Composite Anti-Intrusion Beam for Vehicle Impact Resistance

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Solution Overview

Problem

The challenge is to create a lightweight, high-strength anti-intrusion beam for vehicles that balances impact resistance and energy absorption while minimizing material usage, as traditional metal-based solutions are heavy and inefficient in terms of fuel consumption.

Innovation Solution

A multi-layer composite structure comprising fibrous materials with specific orientation angles and elastic moduli, where the first fibrous material aligns with the longitudinal axis under load, and the second fibrous material provides elongation to prevent splitting, with an optional third material for high impact energy absorption, all bonded with resin, optimizing mechanical properties and weight reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal materials are used for anti-intrusion beam, then strength and impact resistance are improved, but weight increases

Engineering Contradiction:

Improveimpact resistanceVSAvoidbeam weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials consisting of multiple fibrous material layers (e.g., carbon fiber, aramid fiber, glass fiber) combined with resin matrices to create an anti-intrusion beam that achieves high strength and impact resistance while maintaining low weight. The composite structure replaces traditional metal materials, resolving the contradiction between strength and weight by leveraging the high strength-to-weight ratio of fiber-reinforced composites.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The beam is segmented into multiple functional layers, each with specific fiber orientations and material properties. The composite structure is divided into layers with fibers oriented at different angles (e.g., 0°, ±45°, 90°) to distribute and absorb impact energy effectively, allowing the beam to achieve superior mechanical properties without increasing overall weight.

Inventive Principle:

Principle #1Segmentation

2Loss of energy

If fiber layers are oriented at non-zero angles, then impact energy absorption is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveimpact energy absorptionVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent optimizes fiber orientation parameters by arranging fibers at specific angles (e.g., 0°, ±45°, 90°) in different layers to maximize impact energy absorption. This parameter optimization allows the composite beam to dissipate impact energy through fiber buckling, breaking, and matrix cracking while maintaining manufacturability through standardized layup sequences that can be implemented using conventional composite manufacturing processes.

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

The composite structure effectively absorbs impact energy, maintains structural integrity, and reduces material usage, resulting in a safer, lighter, and more fuel-efficient anti-intrusion beam that meets stringent safety and environmental requirements.

Implementation Method 1

a first fibrous material having a first effective elastic modulus, the first fibrous material comprising one or more layers comprising fibers of a first type being arranged with one or more orientation angles relative to a longitudinal axis of the beam, such that a predetermined load applied to the beam from a direction substantially perpendicular to its longitudinal axis drives the fibers of the first type towards alignment with the longitudinal axis of the beam

Methodology Applied

Scientific EffectFiber alignment under load:

Implementation Method 2

a first fibrous material having a first effective elastic modulus... such that a predetermined load applied to the beam... drives the fibers of the first type towards alignment with the longitudinal axis of the beam

Methodology Applied

Scientific EffectEnergy absorption through deformation:

Implementation Method 3

a second fibrous material having a second effective elastic modulus, the second fibrous material comprising one or more layers comprising fibers of a second type, the second fibrous material being selected to provide effective elongation of the beam which prevents splitting of the beam under application of the predetermined load

Methodology Applied

Scientific EffectElongation to prevent splitting: Elasticity

Implementation Method 4

all bonded with resin

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS20220105704A1Impact absorbing structures and methods of manufacturing

Publication Date: 2022.04.07 PLASAN SASA LTD

AI summary

An impact-resisting beam is provided, the beam comprising a multi-layer composite structure, the composite structure comprising first and second fibrous materials, the first fibrous material having a first effective elastic modulus and comprising one or more layers comprising fibers of a first type being arranged with one or more orientation angles relative to a longitudinal axis of the beam such that a predetermined load applied to the beam from a direction perpendicular to its longitudinal axis drives the fibers of the first type towards alignment with the longitudinal axis of the beam, the second fibrous material having a second effective elastic modulus and comprising one or more layers comprising fibers of a second type, the second fibrous material being selected to provide effective elongation or deformation of the beam which prevents splitting of the beam under application of the predetermined load.