CFRP Vehicle Door Impact Beam Segmented Structure
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Solution Overview
Problem
The existing impact beam structures in vehicle doors, particularly those made of carbon fiber reinforced plastics (CFRP), require optimization to reduce weight and complexity while maintaining strength and preventing exterior appearance deterioration during side collisions.
Innovation Solution
A roll-forming method is used to create an impact beam structure with separately molded outer and inner impact beams, coupled to an inner CFRP panel using adhesives, reducing the number of installation parts and enhancing rigidity, with closed cross-sections and connection flanges for improved safety and reduced noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional steel impact beams are used in vehicle doors, then strength and collision protection are ensured, but vehicle weight increases leading to higher fuel consumption
Solution Approach 1:
The patent applies composite materials by using CFRP (carbon fiber reinforced plastic) to manufacture the impact beam structure. The inner panel and impact beams are formed from CFRP material, which provides high strength-to-weight ratio, ensuring collision protection while reducing vehicle door weight compared to traditional steel impact beams
Solution Approach 2:
The impact beam structure is segmented into multiple components: an inner impact beam and an outer impact beam, which are separately molded and then coupled together. This segmentation allows optimization of each component's structure and facilitates assembly while maintaining overall strength
2Strength
If multiple parts are used for impact beam installation, then structural integrity is improved, but device complexity and number of installation parts increase
Solution Approach 1:
The patent merges the inner impact beam and outer impact beam into a coupled structure that functions as an integrated impact beam system. The connection flange bonds these components together to form a unified structure with enhanced structural integrity while reducing the number of separate installation parts
Solution Approach 2:
The patent introduces a connection flange as a bonding interface between the inner and outer impact beams. This additional dimensional element (the flange structure) enables reliable coupling while maintaining a relatively simple overall design
3Ease of operation
If impact beam installation methods are used that compromise exterior appearance, then ease of installation is improved, but exterior appearance deteriorates
Solution Approach 1:
The patent applies local quality by using spot welding specifically at the connection flange location to bond the inner and outer impact beams. This localized bonding method provides strong structural connection while maintaining the aesthetic appearance of the door exterior, as the welding is confined to a specific area that does not compromise overall appearance
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
This approach effectively minimizes weight, enhances passenger safety during side collisions, reduces noise, and maintains the exterior appearance of the vehicle door by optimizing the impact beam's cross-sectional structure and simplifying installation, thereby improving marketability.
Implementation Method 1
bonded to an inner panel of the CFRP door by using an adhesive
Implementation Method 2
The connection flange of the outer impact beam and the connection flange of the inner impact beam may be bonded to each other by spot welding
Data Source
AI summary
A method includes molding an outer impact beam made of carbon fiber reinforced plastics (CFRP) and separately molding an inner impact beam made of CFRP. The outer impact beam and the inner impact beam are coupled to each other to form an impact beam and the impact beam is coupled to an inner panel of a vehicle door.