Bolted Hollow Element Reinforcement for Vehicle Body

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Solution Overview

Problem

Structural reinforcement of vehicle body components, such as doorframes, often compromises stability due to local material weakening at weld seams during the welding process, leading to potential premature failure under heavy loads like those encountered in vehicle crashes.

Innovation Solution

A structurally reinforced hollow element design featuring a bolt with a radial bolt head and a second axial end fastened resistantly to a diametrically opposite wall portion, creating a clearance that prevents premature deformation and allows for energy absorption during high loads, without compromising stability under normal conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If weld seams are used to connect shell elements in hollow elements, then structural reinforcement is achieved, but local material weakening occurs at the weld seams leading to reduced strength and potential premature failure

Engineering Contradiction:

Improvestrength of hollow elementVSAvoidreliability of weld seam

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The connection system is segmented into distinct components: the hollow element, the connection element (bolt or rivet), and the reinforcement element. This segmentation allows the connection element to pass through the hollow element without requiring weld seams, thereby avoiding local material weakening while still achieving structural reinforcement through mechanical fastening.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A connection element (bolt or rivet) is introduced as an intermediary component to join the reinforcement element to the hollow element. This intermediary eliminates the need for direct welding of the hollow element material, preventing local material weakening while maintaining connection strength through the mechanical fastener.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Weight of moving object

If vehicle body panels are designed thin for weight saving, then fuel consumption is reduced, but stability and safety of the vehicle body are compromised

Engineering Contradiction:

Improveweight of vehicle bodyVSAvoidstability of vehicle body

Core Design Contradiction:

Weight of moving objectVSStability of the object's composition

Solution Approach 1:

Instead of uniformly thickening the entire vehicle body panels, the invention applies local reinforcement elements at specific critical locations where additional strength is needed. The connection element and reinforcement element are positioned to provide targeted structural support, maintaining thin panel design overall while enhancing stability at key areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention creates a composite structure combining the thin hollow element (vehicle body panel) with separate reinforcement elements and connection elements. This composite approach allows the thin panel to maintain its weight advantage while the added reinforcement components provide the necessary structural stability and safety.

Inventive Principle:

Principle #40Composite materials

3Force

If structural reinforcement is added to hollow elements, then load-bearing capacity is increased, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveload-bearing capacityVSAvoidcomplexity of reinforcement structure

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The connection element is designed to serve multiple functions simultaneously: it mechanically fastens the reinforcement element to the hollow element, provides structural reinforcement, and eliminates the need for weld seams. This multi-functionality reduces overall device complexity compared to using separate components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention employs simple, readily available connection elements (bolts or rivets) and reinforcement elements that can be easily manufactured and installed. These components are designed to be straightforward and economical, avoiding complex custom-engineered solutions while achieving the required load-bearing capacity enhancement.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS10814919B2Structurally reinforced hollow element and a vehicle body comprising said structurally reinforced hollow element

Publication Date: 2020.10.27 FORD GLOBAL TECH LLC

AI summary

A structurally reinforced hollow element includes a wall which surrounds a cavity at least in part. The wall extends three-dimensionally in such a manner that it comprises (a) a first wall portion with an opening and a second wall portion which is situated diametrically opposite the first wall portion and is spaced apart from the first wall portion, and (b) a bolt. The bolt includes at its first axial bolt end a bolt head that protrudes in the radial direction beyond a head-side bolt extent. The bolt also includes a second axial bolt end, which is remote from the first axial bolt end, is fastened on the second wall portion in a manner that is resistant to axial displacement. An overall clearance remains between an outside surface of the first wall portion and a radial surface of the bolt head which faces the outside surface.