Composite Vehicle Cross Member with Integrated Laminates
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Solution Overview
Problem
Existing car cross beams, regardless of material, often face issues such as being too heavy, increasing assembly time and cost, requiring complex multi-piece constructions, and necessitating high tool maintenance, which complicates assembly and increases weight and expense.
Innovation Solution
The development of vehicle cross members featuring a composite body with a plastic material and laminates, where the laminates are integrated into the structure to provide strength and stiffness, reducing the need for separate mounting components and simplifying the assembly process, while using open channels to facilitate molding and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel and heavy metals are used for cross beams, then structural strength and rigidity are improved, but weight increases and vehicle performance decreases
Solution Approach 1:
The patent applies composite materials by combining plastic material with embedded laminates (fiberglass, carbon fiber, or other reinforcement materials) to create a cross beam that achieves metal-level strength while significantly reducing weight. The composite structure provides both the structural integrity needed for safety and the weight reduction necessary for improved vehicle performance.
Solution Approach 2:
The patent implements local quality by strategically placing laminates within specific regions of the cross beam where strength and stiffness are most needed, rather than uniformly distributing material throughout. This allows the beam to have varying material properties in different locations, optimizing both weight and structural performance.
2Ease of manufacture
If multi-piece construction is used, then manufacturing flexibility is improved, but assembly complexity and time increase
Solution Approach 1:
The patent merges multiple components into a single integrated molded piece. The cross beam is formed as one unified structure with mounting points, supports, and structural elements all incorporated into the single molded component, eliminating the need for separate brackets and fasteners that would require assembly.
Solution Approach 2:
The patent implements multi-functionality by designing the cross beam to perform multiple functions within a single component. The beam provides structural support, incorporates mounting points for various vehicle components, includes integrated brackets, and offers attachment features for seat belts and other safety systems, all in one molded piece.
3Weight of moving object
If lighter-weight metals like aluminum are used, then weight is reduced, but manufacturing cost and tool maintenance increase
Solution Approach 1:
The patent uses composite materials as an alternative to lightweight metals like aluminum. The plastic matrix combined with laminate reinforcement provides comparable strength-to-weight ratio without the high material costs and specialized manufacturing requirements associated with aluminum casting and forming.
Solution Approach 2:
The patent substitutes the traditional metal forming and casting processes with plastic molding techniques. This replacement eliminates the need for expensive aluminum casting equipment and high-temperature processing tools, using instead standard plastic injection or compression molding processes that are more cost-effective and require less maintenance.
4Weight of moving object
If composite materials are used, then weight is reduced, but molding process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning the laminates within the mold cavity before the plastic material is introduced. This allows the reinforcement materials to be correctly placed in their final positions during the molding process itself, eliminating the need for separate post-molding assembly steps and reducing overall process complexity.
Data Source
AI summary
This disclosure includes vehicle cross members and related methods. Some cross members include an elongated beam having a sidewall extending between first and second ends to define a first channel extending along a longitudinal axis of the beam and across at least longitudinally adjacent first and second sections of the beam, the first channel being open on a first side of the beam, and a second channel extending along the longitudinal axis and across at least the second section, the second channel being disposed below the first channel and open on a second side of the beam that is opposite the first side. Some cross members include a composite body having a plastic material and one or more laminates, where the body defines the beam such that at least one of the laminate(s) borders a majority of an inner cross-sectional perimeter of each of the first and second channels.