Auxiliary Cross-Member Structure with Composite Reinforcement
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Solution Overview
Problem
Existing cross-member structures for motor-vehicle front suspension are complex, costly, and heavy, with multiple connection points that complicate assembly and do not adequately address torsion deformation strength requirements.
Innovation Solution
A lightweight, low-cost auxiliary cross-member structure featuring a single metal sheet frame folded into a hollow shell with composite material reinforcement, reducing the number of connection points and eliminating unnecessary uprights, while maintaining strength through a hybrid metallic and composite material composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a single metal sheet frame folded into a hollow shell is used, then weight is reduced and manufacturing is simplified, but strength against torsion deformation may be compromised
Solution Approach 1:
The patent applies composite materials by integrating reinforcement elements (such as ribs, stiffeners, or composite material layers) into the metal sheet frame structure. This allows the hollow shell to maintain reduced weight while achieving sufficient torsion deformation strength through the synergistic combination of the lightweight metal sheet and the reinforcing elements.
Solution Approach 2:
The patent utilizes curved or folded surfaces in the metal sheet frame design, transforming flat metal sheets into three-dimensional hollow shells with optimized geometric shapes. These curved structures inherently provide better structural strength and torsion resistance compared to flat equivalents, while maintaining the weight reduction benefits of the single-sheet construction.
2Ease of manufacture
If the number of connection points is reduced, then assembly is simplified and manufacturing cost is reduced, but connection reliability may be compromised
Solution Approach 1:
The patent merges multiple functions into the reduced number of connection points. Each connection point is designed to simultaneously handle multiple loads and provide multiple functions (e.g., both structural support and suspension mounting). This consolidation maintains reliability by ensuring each connection point is robustly designed to compensate for the reduced quantity.
Solution Approach 2:
The connection points in the patent are designed with multi-functionality, serving both as structural support elements and as mounting points for suspension components. This universal design allows the same connection point to fulfill multiple roles, ensuring that reducing the number of connection points does not compromise the overall system reliability.
3Device complexity
If unnecessary uprights are eliminated, then device complexity is reduced and cost is reduced, but structural support function may be compromised
Solution Approach 1:
The patent extracts or removes unnecessary uprights from the traditional cross-member structure, eliminating redundant structural elements that do not contribute to the primary load-bearing functions. The remaining structure is optimized to provide all necessary support functions through the folded metal sheet configuration, reducing complexity while maintaining strength.
Solution Approach 2:
The patent segments the structural support function into different zones within the hollow shell, with specific folded sections and reinforcement elements strategically positioned to handle different load types. This segmentation allows the structure to maintain comprehensive support capability without requiring all traditional upright elements.
Data Source
AI summary
An auxiliary cross-member structure for supporting elements of a motor-vehicle front suspension includes a metal sheet hollow frame in a form of a hollow shell, with two opposite end portions, for connection of two respective oscillating arms of the suspension. The metal sheet hollow frame is defined by a single metal sheet folded on itself and having portions which are overlapped and welded. In a preferred implementation, within the metal sheet hollow frame is provided an additional filling structure at least partially constituted of synthetic material or composite material incorporating reinforcing fibers. At each end of the auxiliary cross-member structure there are two pairs of holes aligned with each other along two vertical axes which are used both for mounting elastic bushings for connection of a respective oscillating arm, and for the engagement of connecting screws for connecting the auxiliary cross-member structure to the motor-vehicle body.