Self-supporting, large area, motor vehicle body panel comprises facing layers joined to a stiffening plate whose adjacent three-dimensional impressions face in opposite directions

摘要

Two facing layers(1,2) and a stiffening plate(3) between them are joined to form a flat honeycomb structure(4). The stiffening plate has three-dimensional impressions(7) facing in opposite directions and facing layers contact the impressions. Adjacent impressions have a common sidwall(8). Impressions(7) are hollow and may have a cubic, parallelepiped, prismatic, tetrahedron, pyramid and/or truncated pyramid shape. Impression sidewalls are flat and/or curved. Curved sidewalls are designed to absorb forces acting on the honeycomb structure(4). The transverse intersecting sidewalls(8) of the impressions form a unified structure at whose intersections the applied forces are in balance and in conjunction with the facing layers(1,2) forms a stable structure. Tensile forces exerted acting on the facing layers during a vehicle impact are absorbed by the honeycomb structure to prevent separation of the layers. The honeycomb structure may be flat or curved to allow it to follow a vehicle body profile, either uniformly or in steps. Facing layers are bonded(12) and/or welded onto to the stiffening plate(3). Supporting structures and/or other reinforcements and/or fasteners and/or other components elements may be incorporated in the honeycomb. An independent claim is included for a process for manufacturing the component in which: i) a sheet is pressed to form a stiffening plate(3) with impressions running in alternate directions and adjacent impressions having a common sidewall; ii) facing layers are placed on both sides of the formed stiffening plate(3) and joined to the latter to form a honeycomb structure(4).