Vehicle Side Step Weight Reduction Using CFT Insert-Molding

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Solution Overview

Problem

Conventional vehicle side steps are heavy, limiting gas mileage improvement and offering low design flexibility with high manufacturing costs due to the use of aluminum or steel materials.

Innovation Solution

The method involves integrally manufacturing side step components using continuous fiber thermoplastic (CFT) materials through insert-molding, combining injection-molding of brackets and main frames with a locking mechanism to reduce weight and enhance structural rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional side steps are manufactured using aluminum or steel materials, then structural strength and rigidity are ensured, but vehicle weight increases and gas mileage deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by integrating thermoplastic resin with continuous fibers (such as glass fibers or carbon fibers) to create a side step that combines the light weight of polymers with the high strength of fibers. This composite structure achieves comparable structural strength to aluminum or steel while significantly reducing vehicle weight, thereby improving gas mileage without sacrificing structural integrity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by transitioning from traditional metals (aluminum/steel) to fiber-reinforced thermoplastic composites. This parameter change involves adjusting fiber orientation, resin matrix properties, and composite layering to achieve the required strength-to-weight ratio, enabling weight reduction while maintaining structural strength

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If conventional side steps are manufactured using aluminum or steel materials, then structural rigidity is ensured, but design flexibility is limited and manufacturing cost increases

Engineering Contradiction:

Improvestructural rigidityVSAvoiddesign flexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent utilizes the inherent flexibility of thermoplastic resin parameters (viscosity, melting point, curing characteristics) to enable complex geometric shaping and integrated design features that are difficult or expensive to achieve with metal forming processes. This allows for optimized structural rigidity through design rather than material alone

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent merges multiple components (side step body, mounting brackets, reinforcement elements) into a single integrated composite structure manufactured in one process. This consolidation eliminates the need for separate metal parts and assembly operations, enhancing design flexibility while maintaining structural rigidity through the integrated composite design

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If conventional side steps are manufactured using aluminum or steel materials, then structural strength is ensured, but manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent combines material forming and structural creation into a single injection molding process for fiber-reinforced thermoplastic composites. This eliminates multiple manufacturing steps (cutting, bending, welding, fastening) required for metal side steps, significantly reducing manufacturing cost while maintaining structural strength through the integrated composite design

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the manufacturing process parameters from high-cost metal forming (extrusion, stamping, welding) to lower-cost composite injection molding. By adjusting resin flow, fiber alignment, and curing parameters during molding, the process achieves structural strength comparable to metal at a fraction of the manufacturing cost

Inventive Principle:

Principle #35Parameter changes

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 reduces the weight and manufacturing cost of side steps while improving design flexibility and structural rigidity, enhancing marketability and crash-worthiness.

Implementation Method 1

primarily heating the CFT materials to a predetermined temperature

Methodology Applied

Scientific EffectThermal heating: Heating

Implementation Method 2

insert-molding a main frame by injecting an injection molding resin to all over the insert main body coupled to the bracket

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 3

molding the layered CFT materials after secondarily heating the layered CFT materials to a predetermined temperature

Methodology Applied

Scientific EffectThermal molding:

Data Source

PatentUS10307946B2Method of making side step for vehicle

Publication Date: 2019.06.04 HYUNDAI MOTOR CO LTD

AI summary

A method of making a side step of a vehicle includes a bracket that is mounted to a vehicle body and an insert main body that bears weight of passengers. The bracket and the insert main body are integrally provided by using a CFT material through insert-molding, and an injection molding resin is coupled to all over the insert main body where the bracket is coupled through insert-molding so as to form a main frame of the side step.