Adjustable Tubular Reinforcing Element for Vehicle Impact Protection
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Solution Overview
Problem
Existing motor vehicle body designs face challenges in protecting electric and hybrid vehicles from high-energy rear and side impacts while maintaining a streamlined silhouette and economical rear axle systems, as current reinforcement methods increase mass and cost.
Innovation Solution
A tubular reinforcing element comprising longitudinally positioned steel or aluminum tubes with a rigid contact surface and energy-absorbing means, allowing the vehicle to move during rear impacts and providing side impact protection, while being adjustable and adaptable to different wheelbases and overhangs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing motor vehicle body designs are used with standard reinforcement methods, then protection against rear and side impacts is provided, but vehicle mass increases and cost increases
Solution Approach 1:
The reinforcement element is divided into multiple functional segments: energy absorption means (collapsible structure) at the rear, rigid contact surface in the middle, and tubular structure extending forward. This segmentation allows different parts to perform specialized functions - energy absorption where needed and structural support where required - optimizing protection while minimizing unnecessary mass
Solution Approach 2:
The energy absorption means is designed to change its structural parameters dynamically during impact - transitioning from a collapsed state during normal operation to an expanded, load-bearing state during rear impact. This parameter change allows the structure to provide protection only when needed, reducing mass during normal vehicle operation
2Reliability
If existing motor vehicle body designs are used with standard reinforcement methods, then protection against rear and side impacts is provided, but manufacturing cost increases
Solution Approach 1:
The reinforcement element serves multiple functions within a single integrated structure: it provides rear impact protection through energy absorption, side impact protection through rigid contact surfaces, and structural stiffening through tubular elements. This multi-functionality eliminates the need for separate reinforcement components, reducing manufacturing complexity and cost
Solution Approach 2:
The reinforcement element combines different material properties within a single structure - energy-absorbing materials in the collapsible rear section, rigid materials in the contact surface and tubular sections. This composite approach allows optimization of each section for its specific function while maintaining overall structural integrity, reducing total material cost
3Reliability
If a rigid substructure is attached to the rear of the vehicle for protection, then impact protection is improved, but the vehicle cannot move freely during rear-end collision
Solution Approach 1:
The energy absorption means is designed with dynamic characteristics - it remains collapsible and flexible during normal vehicle operation and low-energy impacts, allowing the vehicle to move freely. During high-energy rear-end collisions, it transitions to a rigid, load-bearing state that provides protection while permitting controlled vehicle movement
4Reliability
If reinforcement elements are added to protect batteries and fuel tanks, then component protection is improved, but steel consumption increases
Solution Approach 1:
The reinforcement element provides enhanced protection specifically at locations where components need protection - the energy absorption means protects rear-mounted batteries, while rigid contact surfaces protect side-mounted components. This localized quality approach concentrates steel consumption only where protection is critical, rather than uniformly reinforcing the entire vehicle structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively protects critical components like batteries and fuel tanks from impacts, reduces vehicle mass, and is cost-effective by minimizing steel consumption, allowing for a more economical rear axle system and improved vehicle mobility during crashes.
Implementation Method 1
energy absorption means projecting vis-à-vis the rigid contact surface and to be positioned towards the rear of the vehicle, so that the impactors only come into function for said setting in motion if the energy absorption means have been stressed and overcome by such a rear-end impact
Implementation Method 2
a rigid contact surface comprising impactors, the rigid contact surface being arranged vis-à-vis the two tubes to allow the vehicle to be set in motion in the event of a rear-end impact
Data Source
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AI summary
A reinforcing element (10) for a motor vehicle body (1) comprising protection means (30, 31, 40, 41, 42) for protection against an impact at the rear of the vehicle, characterised in that it comprises at least two tubes (20, 22) to be positioned, generally, in the length direction of the vehicle, and a rigid contact surface (30, 31, 70) turned towards the rear, the rigid contact surface (30, 31, 70) and the two tubes (20, 22) being arranged with respect to each other in order to allow the vehicle to move in case of an impact at the rear.