Composite Vehicle Back Beam for Lightweight Impact Absorption

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Solution Overview

Problem

Conventional vehicle back beams made of steel are heavy, leading to reduced fuel efficiency and increased weight, which negatively impacts driving performance and collision safety, while alternative materials like plastics lack sufficient strength and rigidity for effective impact absorption.

Innovation Solution

A vehicle back beam utilizing a large-deformable composite laminate composed of fiber-reinforced sheets with specific orientations and a resin matrix, providing high elongation and energy absorption capabilities while maintaining mechanical strength and rigidity, thereby enhancing collision performance and reducing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If steel material is used for back beam, then high strength and rigidity are achieved, but weight increases reducing fuel efficiency

Engineering Contradiction:

Improveimpact absorption strengthVSAvoidback beam weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining fiber-reinforced plastic sheets (providing strength and rigidity) with a metal core (providing ductility and energy absorption). This composite structure achieves the mechanical properties of steel while significantly reducing weight, as the fiber-reinforced plastic has much lower density than steel while maintaining comparable strength-to-weight ratio.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by using different materials in different regions of the back beam. The fiber-reinforced plastic sheets are positioned in areas requiring high strength and rigidity, while the metal core is placed in regions needing ductility and energy absorption. This localized material distribution optimizes both weight and mechanical performance.

Inventive Principle:

Principle #3Local quality

2Weight of moving object

If plastic material is used for back beam, then weight is reduced improving fuel efficiency, but strength and rigidity are insufficient for effective impact absorption

Engineering Contradiction:

Improveback beam weightVSAvoidimpact absorption strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses composite materials to overcome the limitations of pure plastic. By combining fiber-reinforced plastic (lightweight) with metal core (strong), the composite structure achieves both weight reduction and sufficient impact absorption strength, eliminating the weakness of pure plastic while maintaining its weight advantage.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by selecting specific fiber orientations, resin types, and metal core compositions to optimize the balance between weight and strength. The fiber-reinforced plastic is engineered with specific tensile strength and modulus values that compensate for the lower density, achieving comparable mechanical performance to steel at reduced weight.

Inventive Principle:

Principle #35Parameter changes

3Weight of moving object

If conventional fiber reinforced composite is used, then weight is reduced, but elongation and energy absorption are insufficient for maximizing collision performance

Engineering Contradiction:

Improveback beam weightVSAvoiddeformation duration during impact

Core Design Contradiction:

Weight of moving objectVSDuration of action of moving object

Solution Approach 1:

The patent uses a dual-material composite where fiber-reinforced plastic provides elastic deformation capability (high elongation) and metal core provides plastic deformation capability (energy absorption). This combination extends the deformation duration during impact, allowing the back beam to absorb more energy over a longer period, thereby maximizing collision performance while maintaining lightweight construction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements dynamics by creating a structure that transitions from elastic to plastic deformation. The fiber-reinforced plastic undergoes elastic deformation first, then the metal core undergoes plastic deformation, creating a dynamic, multi-stage energy absorption process that maximizes deformation duration and energy dissipation.

Inventive Principle:

Principle #15Dynamics

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 large-deformable composite back beam achieves improved elongation, energy absorption, and mechanical properties similar to steel, while significantly reducing weight, thus enhancing collision performance and fuel efficiency.

Implementation Method 1

a back beam body (3), and a back beam reinforcing portion formed across at least one section of the back beam body, wherein the back beam reinforcing portion includes a large-deformable composite

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11878642B2Vehicle back beam and vehicle including same

Publication Date: 2024.01.23 LG HAUSYS LTD

AI summary

Disclosed are a vehicle back beam capable of maximizing impact performance and reducing product weight; and a vehicle including same. According to one embodiment of the present invention, provided is a vehicle back beam which includes: a back beam body; and a back beam reinforcing part which is formed in at least one section of the back beam body and composed of a highly deformable composite material.