I-Section Beam with Ribbing for Crash Rail Backup
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Solution Overview
Problem
Existing structural members for vehicles, particularly those connecting bumpers to mid-vehicle structural members, are often heavy, expensive, and difficult to manufacture, and may require repair before installation, limiting their effectiveness in handling road conditions and crash scenarios.
Innovation Solution
A structural beam component with an I-section and ribbing, manufactured using high-pressure die casting, which provides a backup structure for crash rails and connects to side sills, facilitating energy absorption and reducing weight through optimized ribbing patterns and attachment points, while maintaining stiffness and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low-pressure casting is used to manufacture structural members, then the manufacturing process is simpler, but the resulting part is heavy, expensive, and difficult to make with acceptable quality
Solution Approach 1:
The patent transitions from low-pressure casting to high-pressure die casting, fundamentally changing the manufacturing parameter (pressure level) to achieve lighter weight parts with better structural properties while maintaining manufacturing feasibility
Solution Approach 2:
The structural member incorporates composite features through integrated ribbing and I-section geometry combined with high-pressure die casting material properties, creating a optimized composite structure that reduces weight while maintaining strength
2Ease of manufacture
If low-pressure casting is used to manufacture structural members, then the manufacturing process is simpler, but the part requires repair and re-working before installation
Solution Approach 1:
By changing from low-pressure to high-pressure die casting, the manufacturing process achieves superior dimensional accuracy and surface finish, eliminating the need for post-manufacturing repair while maintaining process simplicity through integration
Solution Approach 2:
The patent merges multiple features (ribbing, I-section geometry, attachment points) into a single integrated high-pressure die cast component, achieving high manufacturing precision in one process step without requiring subsequent repair operations
3Strength
If traditional structural members are used, then sufficient strength is provided, but the parts are heavy and expensive
Solution Approach 1:
The structural member features localized ribbing and I-section geometry that concentrate material where strength is needed, while maintaining thinner walls and reduced material in non-critical areas, achieving optimal strength-to-weight ratio
Solution Approach 2:
The combination of high-pressure die casting material properties with optimized I-section and ribbing geometry creates a composite-like structure that provides maximum strength with minimum weight
4Strength
If traditional structural members are used, then sufficient strength is provided, but the manufacturing complexity and cost increase
Solution Approach 1:
Multiple structural features (ribbing, I-section profile, attachment points, and reinforcement geometries) are merged into a single high-pressure die cast component, reducing manufacturing complexity while maintaining structural strength
Solution Approach 2:
The adoption of high-pressure die casting technology enables complex geometries to be manufactured with relative simplicity by changing the fundamental manufacturing parameter, achieving both strength and manufacturing efficiency
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 reduces material costs, weight, and manufacturing complexity, enhancing the vehicle's ability to absorb impact energy and protect sensitive components by providing a robust yet lightweight backup structure for crash rails, improving noise-vibration-harshness characteristics and durability.
Implementation Method 1
manufactured using high-pressure die casting
Data Source
AI summary
A structural beam component for a vehicle comprises: a beam body that has an I-section for at least part of its length, the beam body having first and second sides opposite each other, wherein the I-section extends at least partially along the first and second sides; a crash rail attachment at one end of the beam body, the crash rail attachment providing a fore-aft backup structure for a crash rail in the vehicle; another attachment at an opposite end of the beam body, the other attachment connecting the structural beam component to a side sill of the vehicle; and first and second ribbing on the first and second sides, respectively.