Bracket-Integrated Double-Layer Door Impact Beam
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing door impact beams for vehicles face a trade-off between high strength and weight, with increased strength leading to brittleness and a higher risk of fracture, and the use of single steel pipes resulting in increased weight and reduced elongation.
Innovation Solution
A bracket-integrated double-layer door impact beam is manufactured with a double layer structure only in areas requiring strength reinforcement, using a quenchable steel material and a strength reinforcing member bonded to the external pipe, which is heat-treated to increase tensile strength and reduce weight, while the bracket is integrally formed with the impact beam to minimize parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the strength of the impact beam is increased using high strength material, then the impact absorption capability is improved, but the brittleness increases and the risk of fracture increases
Solution Approach 1:
The patent applies different material properties to different parts of the impact beam. The first end portion (requiring high strength) uses high strength material, while the second end portion (requiring toughness) uses material with lower strength but higher elongation. This local differentiation resolves the contradiction by providing high impact absorption where needed while maintaining reliability through elongation in other areas.
Solution Approach 2:
The impact beam is constructed as a composite structure with two different materials: a high strength material for the first end portion and a material with higher elongation for the second end portion. This composite approach allows the beam to simultaneously achieve high strength for impact absorption and sufficient elongation to prevent fracture.
2Strength
If the thickness of the single steel pipe is increased to secure rigidity, then the structural strength is improved, but the weight increases substantially
Solution Approach 1:
Instead of uniformly increasing the thickness of the entire beam, the patent applies the double-layer structure only to the first end portion where high rigidity is required. The second end portion maintains a single-layer structure with lower thickness, thereby achieving the necessary rigidity locally without substantially increasing the overall weight of the beam.
Solution Approach 2:
The impact beam is segmented into different structural configurations: the first end portion uses a double-layer structure for high rigidity, while the second end portion uses a single-layer structure. This segmentation allows weight optimization by providing structural reinforcement only where absolutely necessary.
3Device complexity
If a single steel pipe is used to simplify the structure, then the manufacturing process is simplified, but the weight increases and elongation decreases
Solution Approach 1:
The beam is divided into two segments with different structural configurations: a double-layer structure in the first end portion and a single-layer structure in the second end portion. This segmentation reduces weight compared to a uniform single-layer design while avoiding the complexity of a complete double-layer structure throughout the entire beam.
4Strength
If the double layer structure is applied to the entire impact beam to ensure high strength, then the strength is maximized, but the weight increases substantially
Solution Approach 1:
The double-layer structure is applied locally only to the first end portion where high strength is critical, while the second end portion uses a lighter single-layer structure. This local application maintains overall strength where needed while substantially reducing the total weight compared to a full double-layer construction.
Solution Approach 2:
Instead of applying the double-layer structure to the entire beam (excessive action), the patent applies it partially only to the first end portion where it is most needed. This partial application achieves sufficient strength while avoiding the excessive weight penalty of full double-layer construction.
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 achieves high strength and reduced weight by selectively applying a double layer structure and heat-treating the steel, enhancing tensile strength while maintaining elongation, thus reducing the risk of fracture and improving deformation resistance during impacts.
Implementation Method 1
an induction heating device configured to heat the base material to a high temperature
Implementation Method 2
a cooling device configured to rapidly cool the heated base material
Data Source
AI summary
An apparatus for manufacturing a bracket-integrated double-layer door impact beam is provided. The apparatus includes a lower mold having a lower cavity formed with a base material molded to have a “U”-shaped cross section and a predetermined length. The base material is seated on the lower cavity. A lower electrode terminal is disposed in the lower mold to contact the base material. An upper mold has an upper cavity therein and is coupled with the lower mold to pressurize both end portions of the “U”-shaped cross section of the base material inward to form the base material with an “O”-shaped cross section. An upper electrode terminal is disposed in the upper mold to contact the base material.