Composite Compression Limiter for Vehicle Sub-Frame Weight Reduction
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Solution Overview
Problem
Conventional metal sub-frames and compression limiters in vehicles are heavy, expensive, and contribute to reduced fuel economy due to their weight, while also facing challenges in meeting structural and impact strength requirements.
Innovation Solution
A composite thermoplastic structure and compression limiter made from polymeric continuous fiber tape reinforced with fibers, such as carbon or glass, which reduces weight and enhances stiffness and impact resistance, eliminating galvanic corrosion and improving creep performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal materials (steel) are used for sub-frame components, then sufficient stiffness and impact strength are achieved, but weight increases and fuel economy decreases
Solution Approach 1:
The patent applies composite materials by replacing traditional metal sub-frame components with thermoplastic composite parts reinforced with continuous fibers (20-65% by weight). This composite construction maintains sufficient stiffness and impact strength while significantly reducing weight compared to steel components, directly resolving the contradiction between strength and weight.
2Reliability
If metal compression limiters are used to prevent creep of thermoplastic parts, then creep resistance is improved, but substantial additional weight is added to the vehicle
Solution Approach 1:
The patent changes the material parameters by replacing metal compression limiters with thermoplastic composite limiters that have comparable mechanical properties. The composite limiters maintain sufficient compressive strength and creep resistance while being significantly lighter than metal alternatives, resolving the contradiction between reliability and weight.
3Reliability
If multiple metal compression limiters are used throughout the vehicle, then structural requirements are met, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent merges the functions of compression limiters into the thermoplastic sub-frame components themselves through integrated design. The thermoplastic parts incorporate built-in creep resistance features and load distribution structures, eliminating the need for separate metal compression limiters and reducing assembly complexity while maintaining structural requirements.
Data Source
AI summary
A composite compression limiter (44) includes a cylindrical body (46) extending axially with an aperture (48) extending axially therethrough to receive a fastener (18), the body (46) being made of a continuous fiber polymeric tape reinforced by a plurality of fibers ranging from approximately 20% to approximately 65% by weight.