Description:FOLDED SHEET METAL PANEL FOR MOUNTING LOAD DISTRIBUTION

FIELD OF INVENTION
[0001] The present disclosure relates to sheet metal panel structures used in three wheeler, for load-bearing applications, and more particularly to a folded sheet metal panel design that distributes mounting loads through at least one folded layer without requiring additional reinforcement components or welding operations.
BACKGROUND
[0002] Sheet metal panels are widely used in various industries, particularly in automotive manufacturing, for structural components that must withstand significant mechanical loads. These panels often serve as mounting surfaces for various components, requiring them to distribute concentrated forces across their surface area to prevent localized failure and maintain structural integrity.
[0003] In conventional approaches, when a thin sheet metal panel must support high loads or high vibration mounting components, additional reinforcement elements are typically employed. These reinforcements usually consist of thicker sheet metal pieces that are positioned at the inner side of the main panel in the local mounting area. The reinforcement pieces are commonly joined to the main panel through spot welding or other joining methods. This approach increases the local modulus and stiffness of the mounting area, enabling the concentrated stresses from the mounting hardware to be distributed more evenly across the panel surface.
[0004] The use of additional reinforcement elements allows manufacturers to employ thinner main panels while still achieving adequate load-bearing capacity at mounting locations. This design strategy can contribute to weight reduction in the overall structure while maintaining performance requirements. The reinforcement approach represents established engineering practice for managing stress concentrations in sheet metal assemblies.
[0005] However, this conventional reinforcement approach presents challenges in certain applications, particularly in areas where welding access is limited or restricted. Closed sections, narrow geometries, and complex structural configurations can make it difficult or impossible to position welding equipment for proper joining of reinforcement elements. In such cases, manufacturers may be compelled to use thicker sheet materials for the entire panel or modify the structural geometry to accommodate welding access requirements. These solutions can result in increased weight and may compromise packaging efficiency.
[0006] Alternative approaches may involve the development of specialized welding equipment designed for restricted access applications, though this can introduce additional manufacturing costs and complexity. The limitations of conventional reinforcement methods in challenging geometric configurations continue to drive the need for alternative solutions that can provide effective load distribution without the constraints associated with welding operations and additional component requirements.
SUMMARY
[0007] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0008] According to an aspect of the present disclosure, a sheet metal panel structure is provided for mounting components subject to high loads or vibrations. The sheet metal panel structure comprises a single sheet metal panel having at least one wall portion configured to receive a mounting component. The wall portion includes at least one layer formed by folding the single sheet metal panel back upon itself at the wall portion to create a locally reinforced area. The at least one layer are configured to distribute concentrated stresses from the mounted component evenly across the panel surface without requiring additional separate reinforcement components.
[0009] According to other aspects of the present disclosure, the sheet metal panel structure may include one or more of the following features. The wall portion may include two, three, or more layers formed by multiple folds of the single sheet metal panel. The at least one layer may be held together by fasteners of the mounting component when a length of the folded panel portion is relatively short. The at least one layer may be held together by adhesives, when a length of the folded panel portion is longer or when forces in the application tend to separate the layers apart. The adhesives may prevent vibrations or noise between the layers. The sheet metal panel structure may form a closed section geometry. The sheet metal panel structure may be manufactured by roll forming. Other wall portions of the single sheet metal panel may remain as a single layer where mounting components are not present.
[0010] According to another aspect of the present disclosure, a method of manufacturing a sheet metal panel structure is provided. The method comprises providing a single sheet metal panel and folding the single sheet metal panel at a wall portion to create at least one layer at the wall portion where a mounting component will be attached. The method includes maintaining other portions of the single sheet metal panel as single layers where mounting components are not required.
[0011] According to other aspects of the present disclosure, the method may include one or more of the following features. The folding may create two, three, or more layers depending on load requirements of the mounted component. The method may include securing the at least one layer together using fasteners of the mounting component or adhesives. The method may eliminate the need for separate reinforcement components and welding operations for joining reinforcements to the panel.
[0012] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.
BRIEF DESCRIPTION OF FIGURES
[0013] Non-limiting and non-exhaustive examples are described with reference to the following figures. FIG. 1 illustrates a front view of a sheet metal panel structure showing multiple folded layers at a mounting location.
[0014] FIG. 2 shows a side view of a sheet metal panel B-pillar structure with a mounting area.
[0015] FIG. 3 illustrates an isometric view of a B-pillar structural component
[0016] FIG. 4 illustrates a cross-sectional view of a sheet metal panel structure showing a folded configuration with a mounting arrangement extending through the folded layers.
DETAILED DESCRIPTION
[0017] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.
[0018] Referring to FIG. 1, a sheet metal panel structure (1) provides a solution for mounting components subject to high loads or vibrations without requiring additional separate reinforcement components. The structure (1) comprises a single sheet metal panel having at least one wall portion (2) configured to receive a mounting component (3). The wall portion (2) includes at least one layer formed by folding the single sheet metal panel back upon itself at the wall portion (2) to create a locally reinforced area. This folding approach allows the at least one layer to distribute concentrated stresses from the mounted component (3) evenly across the panel surface, eliminating the need for traditional welded reinforcement pieces that may be difficult to install in confined spaces.
[0019] The folding configuration may vary based on the specific load requirements of the mounted component (3). In some cases, the wall portion (2) includes two layers formed by folding the single sheet metal panel once back upon itself. For applications requiring greater load distribution capability, the wall portion (2) may include three layers formed by multiple folds of the single sheet metal panel. The panel sheet may be folded into additional layers beyond three, with the number of layers determined by the load requirements of the mounted part. This flexibility in layer configuration allows the structure (1) to be tailored to specific mounting applications while maintaining the single-sheet construction approach.
[0020] With continued reference to FIG. 1, the folded layers may be secured together through various methods depending on the geometric and operational characteristics of the application. When the length of the folded panel portion remains relatively short, the mounting hardware or fasteners (5, 6) themselves may hold the folded layers together during operation. This approach eliminates the need for additional securing mechanisms while providing adequate layer cohesion for load transfer. The fasteners (5, 6) pass through all layers of the folded section, creating a mechanical connection that maintains the integrity of the layered structure under operational loads.
[0021] For applications where the folded panel length extends beyond what the mounting fasteners (5, 6) can effectively secure, or where operational forces may tend to separate the layers apart, suitable adhesives may be used to hold the layers together. The adhesive bonding between layers provides continuous contact across the folded section, preventing relative movement between layers that could lead to vibrations or noise during operation. The adhesive selection may be based on the specific environmental conditions, load characteristics, and material compatibility requirements of the application. This dual approach to layer securing provides design flexibility while maintaining the structural integrity of the folded reinforcement area.
[0022] Referring to FIG. 2, the sheet metal panel structure (1) demonstrates an side view configuration that illustrates the practical implementation of the folded reinforcement approach. The structure (1) shows a main vertical section with a mounting area positioned in the middle portion, where two circular openings are arranged vertically to accommodate fasteners (5, 6) or mounting hardware. The mounting area features the folded layers created through the strategic folding of the single sheet metal panel, providing localized reinforcement at the mounting location while maintaining structural efficiency throughout the remaining panel areas.
[0023] The orthogonal view reveals how the folded panel design creates at least one layer specifically at the mounting location through the folding technique, where the sheet metal may be manipulated to achieve the desired layer configuration. The mounting openings pass through the folded layers, allowing fasteners (5, 6) to engage with all layers simultaneously and create a secure mechanical connection. The vertical arrangement of the mounting points demonstrates how the folded reinforcement area can accommodate multiple attachment points within a single reinforced zone, distributing loads across the layered material while maintaining a compact profile suitable for space-constrained applications.
[0024] Referring to FIG. 3, the isometric view of the structural component (1) demonstrates how the folded sheet metal design enables the formation of a closed section geometry without the constraints typically associated with welding access requirements. The structural component (1) comprises a vertical hollow section with multiple walls forming a rectangular profile, where the sheet metal may be folded into at least one layer at one wall portion (2) while maintaining a single layer construction on the other walls. The closed section configuration provides enhanced structural rigidity and torsional strength compared to open section designs, while the folded reinforcement approach eliminates the manufacturing limitations that conventionally prevent the use of such geometries in mounting applications.
[0025] With continued reference to FIG. 3, the compact profile achieved through the closed section geometry enables dimensional reductions compared to conventional designs that accommodate welding access requirements. The elimination of welding access constraints allows the section size to be reduced by approximately 20 to 25% in the X dimension and 10 to 15% in the Y dimension relative to traditional reinforced panel designs. These dimensional reductions result from the ability to optimize the section geometry for structural performance rather than manufacturing accessibility, as the folded reinforcement approach removes the spatial requirements typically associated with welding gun access and reinforcement component positioning.
[0026] The structural component (1) illustrated in the isometric view demonstrates particular applicability to difficult access areas such as B-pillar structures where conventional welding access may be limited or impossible. B-pillar applications typically involve narrow, enclosed sections where the positioning of welding equipment becomes challenging, often forcing design compromises that increase section dimensions or material thickness to accommodate manufacturing constraints. The folded reinforcement approach addresses these limitations by creating the enhanced load distribution capability through sheet metal manipulation that occurs during the forming process, eliminating the subsequent welding operations that create access challenges in confined geometries.
[0027] As further shown in FIG. 3, the sheet metal panel structure (1) may be manufactured using roll forming processes when the welding access constraints are removed through the folded reinforcement approach. Roll forming enables the continuous shaping of the sheet metal into the desired closed section profile while simultaneously creating the folded reinforcement areas through coordinated forming operations. The roll forming process provides dimensional consistency and material efficiency while accommodating the folded layer configuration within the overall section geometry. The manufacturing approach allows for the integration of the folding operations within the primary forming sequence, streamlining production while maintaining the structural performance characteristics of the reinforced mounting areas.
[0028] Referring to FIG. 4, the cross-sectional view of the panel assembly illustrates the complete implementation of the folded sheet metal design with mounting component (3) installation. The assembly demonstrates how the sheet metal panel curves and folds back upon itself at the mounting location, creating at least one layer that form a locally reinforced area where the mounting component (3) may be attached. The cross-sectional perspective reveals the internal structure of the folded layers and shows how the mounting component (3) extends through the layered material to establish a secure attachment point. The folded configuration allows the at least one layer to work in combination to distribute concentrated stresses from the mounted component (3) across a broader area of the panel surface.
[0029] The mounting component (3) installation shown in the cross-sectional view demonstrates how the folded layers provide enhanced load distribution capability through the layered material structure. When the mounting component (3) transmits loads to the panel, the forces may be distributed across all layers of the folded section rather than concentrating on a single sheet thickness. The at least one layer act collectively to spread the mounting loads over a larger effective area, reducing local stress concentrations that might otherwise lead to material failure. The cross-sectional view shows how the mounting component (3) engages with the folded layers simultaneously, creating multiple load paths through the layered structure that enhance the overall load-carrying capacity of the mounting area.
[0030] With continued reference to FIG. 4, the method of securing the folded layers together may vary depending on the geometric characteristics and operational requirements of the specific application. When the length of the folded panel portion remains relatively short, the mounting component (3) fasteners (5, 6) themselves may hold the at least one layer together during operation. The fasteners (5, 6) pass through all layers of the folded section, creating mechanical compression that maintains layer contact and prevents relative movement between the folded surfaces. This approach eliminates the need for additional securing mechanisms while providing adequate layer cohesion for effective load transfer through the mounting interface.
[0031] For applications where the folded panel length extends beyond what the mounting component (3) fasteners (5, 6) can effectively secure, or where operational forces in the application tend to separate the layers apart, adhesives may be applied between the folded surfaces to hold the layers together. The adhesive bonding creates continuous contact across the entire folded section, maintaining layer integrity even in areas not directly compressed by the mounting fasteners (5, 6). The adhesives prevent vibrations or noise between the layers by eliminating the potential for relative movement or separation that could occur under dynamic loading conditions. The adhesive selection may be based on the environmental conditions, temperature requirements, and chemical compatibility with the sheet metal material to ensure long-term bonding performance.
[0032] As further shown in FIG. 4, the manufacturing approach for the folded panel structure (1) may utilize steel roll forming processes when the welding access constraints are removed through the folded reinforcement design. Roll forming enables the continuous shaping of the sheet metal into the desired profile while simultaneously creating the folded reinforcement areas through coordinated forming operations. The roll forming process may be used instead of sheet metal stamping when the elimination of welding requirements allows for more flexible manufacturing approaches. The continuous forming process provides dimensional consistency and material efficiency while accommodating the folded layer configuration within the overall panel geometry, allowing the folding operations to be integrated within the primary forming sequence rather than requiring separate secondary operations.
[0033] The manufacturing method for creating the folded sheet metal panel structure (1) begins with providing a single sheet metal panel that serves as the base material for the entire structure (1). The single sheet metal panel may be selected based on the specific material properties, thickness requirements, and environmental conditions anticipated for the final application. Material selection considerations may include factors such as tensile strength, corrosion resistance, formability characteristics, and compatibility with subsequent processing operations. The initial sheet metal panel typically maintains uniform thickness throughout, with the enhanced load distribution capability achieved through the subsequent folding operations rather than through material thickness variations.
[0034] The folding process involves manipulating the single sheet metal panel at designated wall portions (2) to create at least one layer at locations where mounting components (3) will be attached. The folding operation may be performed using various forming techniques, including press brake operations, roll forming processes, or specialized folding equipment designed to achieve the desired layer configuration. The folding sequence may be coordinated with other forming operations to integrate the layer creation process within the overall panel shaping workflow. Tooling design for the folding operations may incorporate features that control the fold radius, layer alignment, and dimensional accuracy of the folded sections to ensure consistent layer formation across production quantities.
[0035] The number of layers created through the folding process may vary depending on the load requirements of the mounted component (3) that will be attached to the folded section. In some cases, the folding creates two layers through a single fold operation that brings one portion of the sheet metal panel back upon itself at the designated wall portion (2). The two-layer configuration provides enhanced load distribution capability compared to single-layer construction while maintaining manufacturing simplicity through the single fold operation. The fold geometry may be designed to achieve intimate contact between the two layers, creating a composite structure that distributes mounting loads across the combined thickness of both layers.
[0036] For applications requiring greater load distribution capability, the folding process may create three layers through multiple fold operations performed sequentially at the same wall portion (2). The three-layer configuration involves additional folding steps that bring additional portions of the sheet metal panel into contact with the previously folded layers. The multiple fold sequence may require careful coordination of the folding operations to ensure proper layer alignment and avoid interference between successive folds. Tooling for three-layer formation may incorporate progressive forming stages that accommodate the increasing material thickness as additional layers are added to the folded section.
[0037] The manufacturing process maintains other portions of the single sheet metal panel as single layers where mounting components (3) are not required, preserving material efficiency throughout the structure (1). The selective application of folding operations allows the panel to achieve enhanced load distribution capability only in areas where such capability may be needed, while maintaining the original sheet thickness in areas subject to lower loading conditions. The transition zones between folded and single-layer areas may be designed to provide smooth load transfer paths that avoid stress concentrations at the boundaries between different layer configurations. Manufacturing tooling may incorporate features that control the transition geometry to ensure structural continuity throughout the panel.
[0038] Layer retention methods may be integrated within the manufacturing process to secure the at least one layer together and maintain the integrity of the folded structure during subsequent operations and service conditions. The securing of at least one layer together using fasteners (5, 6) of the mounting component (3) may be accommodated through the manufacturing process by ensuring proper alignment of mounting holes across all layers of the folded section. Hole formation operations may be performed after the folding process to ensure accurate alignment, or pre-formed holes may be positioned to align properly during the folding sequence. The fastener-based retention approach eliminates the need for additional securing mechanisms while providing mechanical compression that maintains layer contact throughout the folded section.
[0039] Alternative layer retention approaches may involve securing the at least one layer together using adhesives applied between the folded surfaces during or after the folding operations. Adhesive application may be integrated within the manufacturing sequence through automated dispensing systems that apply controlled amounts of adhesive material to the sheet metal surfaces before the folding operations bring the layers into contact. Curing processes for the adhesive materials may be incorporated within the manufacturing workflow through heating operations, time-based curing cycles, or chemical activation methods that ensure proper bonding between the folded layers. The adhesive retention approach provides continuous contact across the entire folded section, maintaining layer integrity even in areas not directly compressed by mounting fasteners (5, 6).
[0040] The manufacturing method eliminates the need for separate reinforcement components and welding operations for joining reinforcements to the panel, streamlining the production process while reducing component complexity. The elimination of separate reinforcement components removes the material handling, positioning, and fixturing operations typically associated with reinforcement attachment processes. Welding operations, including spot welding, seam welding, or other joining processes, may be eliminated from the manufacturing sequence, reducing cycle time and eliminating the equipment, energy, and quality control requirements associated with welding processes. The simplified manufacturing approach reduces the number of process steps while maintaining the structural performance characteristics achieved through the folded layer configuration.
[0041] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims. , Claims:I/WE CLAIM
1. A sheet metal panel structure (1), comprising:
a single sheet metal panel having at least one wall portion (2) configured to receive a mounting component (3),
wherein the wall portion (2) includes at least one folded layer formed by folding the single sheet metal panel back upon itself at the wall portion (2) to create a locally reinforced area, and
wherein the at least one folded layer is configured to distribute concentrated stresses from the mounting component (3) evenly across the panel surface without requiring additional separate reinforcement components.

2. The sheet metal panel structure (1) of claim 1, wherein the wall portion (2) includes two or more folded layers formed by multiple folds of the single sheet metal panel, and wherein a number of the folded layers is determined by load requirements of the mounting component (3).

3. The sheet metal panel structure (1) of claim 2, wherein the folded layers are held together by fasteners (5, 6) of the mounting component (3) when a length of a folded panel portion is relatively short, or by adhesives when the length of the folded panel portion is longer or when forces tend to separate the folded layers apart.

4. The sheet metal panel structure (1) of claim 1, wherein the sheet metal panel structure (1) forms a B-pillar in a three wheeler vehicle.

5. A method of manufacturing a sheet metal panel structure (1), comprising:
providing a single sheet metal panel;
folding the single sheet metal panel at a wall portion (2) to create at least one folded layer at the wall portion (2) where a mounting component (3) will be attached; and
maintaining other portions of the single sheet metal panel as single layers where mounting components (3) are not required.
6. The method of claim 4, wherein the folding creates two or more folded layers through multiple fold operations, and wherein a number of the folded layers is determined by load requirements of the mounting component (3).

7. The method of claim 5, further comprising a step of securing the folded layers together using fasteners (5, 6) of the mounting component (3) when a length of a folded panel portion is relatively short, or using adhesives when the length of the folded panel portion is longer or when forces tend to separate the folded layers apart.

8. A sheet metal panel structure (1) for a vehicle B-pillar, comprising:
a single sheet metal panel forming a closed section geometry having multiple walls, wherein at least one wall (2) includes multiple folded layers formed by folding the single sheet metal panel back upon itself multiple times to create a locally reinforced mounting area, and wherein remaining walls of the closed section maintain single layer construction.

9. The sheet metal panel structure (1) of claim 7, wherein the multiple folded layers are held together by fasteners (5, 6) of a mounting component (3) when a length of the locally reinforced mounting area is relatively short, or by adhesives when the length is longer or when operational forces tend to separate the folded layers apart.

10. The sheet metal panel structure (1) of claim 8, wherein the adhesives prevent vibrations or noise between the folded layers by eliminating relative movement between the layers under dynamic loading conditions.