Composite Vehicle Cross-Member for Lightweight Panel Reinforcement
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Solution Overview
Problem
Current cross-member structures for vehicles lack an efficient combination of lightweight materials and structural reinforcement, particularly in supporting vehicle systems like instrument panels, which requires both strength and reduced weight.
Innovation Solution
A composite cross-member assembly featuring a plastic beam structure integrated with a metal structural support section, utilizing materials like steel, aluminum, or magnesium alloys, to provide enhanced reinforcement and support for vehicle systems, including the instrument panel, steering column, and central console.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a plastic beam structure is used for the cross-member, then weight is reduced and manufacturing cost is decreased, but structural strength and reinforcement are insufficient
Solution Approach 1:
The patent applies composite materials by integrating a metal structural support section within the plastic beam structure. The metal section (steel, aluminum, or magnesium alloy) provides the necessary structural strength and reinforcement, while the plastic material maintains lightweight properties and cost-effectiveness. This composite approach resolves the contradiction between weight reduction and strength enhancement.
Solution Approach 2:
The patent merges two different materials (plastic and metal) into a single integrated cross-member structure. The metal structural support section is embedded within or integrated with the plastic beam structure, combining the advantages of both materials: the lightweight and cost-effective plastic exterior with the strong metal reinforcement, thereby achieving both weight reduction and strength improvement.
2Strength
If a metal structural support section is integrated into the plastic beam structure, then structural strength is enhanced, but manufacturing complexity increases
Solution Approach 1:
The metal structural support section and plastic beam structure are merged into a single integrated component. This merging eliminates the need for separate assembly steps, joining operations, and multiple manufacturing processes, thereby reducing manufacturing complexity despite the use of multiple materials. The integrated design simplifies production while maintaining enhanced structural strength.
3Strength
If composite structure with plastic and metal is used, then mechanical performance is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent uses composite materials (plastic and metal) to achieve superior mechanical performance. The metal structural support section provides high strength and stiffness, while the plastic material offers ease of molding and cost-effectiveness. The composite structure optimizes mechanical properties for the cross-member application.
Solution Approach 2:
By merging the metal and plastic components into an integrated structure, the patent eliminates the need for complex post-assembly processes such as welding, bolting, or adhesives. The integrated design simplifies the manufacturing process despite using multiple materials, as it can be produced in a single molding or assembly operation.
Data Source
AI summary
A cross-member structure/assembly for a vehicle providing an instrument panel is disclosed. The assembly may comprise a composite structure/assembly comprising a plastic beam structure and a metal structural support section to reinforce the plastic beam structure. The assembly may comprise a metal structural member and/or metal bracket member. The assembly may provide structural reinforcement and integrate vehicle systems/subsystems with the instrument panel. The assembly may comprise a set of sections/segments such as an arrangement of beam/structure sections, mounting sections, and structural elements including members, webs, flanges, stiffeners, reinforcement, plates, walls, surfaces, etc. The assembly may comprise an intermediate structural support section configured to support the beam structure. The metal structural support section may be assembled with the plastic beam structure; the metal structural member may be formed with the plastic beam structure (e.g. insert molding, over-molding, etc.). The metal may comprise an alloy such as steel, aluminum, magnesium, etc.