Composite Vehicle Cross Member for Strength Without Added Weight

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Solution Overview

Problem

Existing vehicle structures face challenges in efficiently distributing weight and absorbing mechanical forces, particularly on varied terrains, leading to potential structural weaknesses and increased material usage.

Innovation Solution

An apparatus comprising an elongated cross member with structural inserts and sleeves that enhance rigidity and weight distribution, utilizing materials like steel, aluminum, and carbon fiber to optimize strength-to-weight ratio and absorb impact forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional vehicle structures use more material to enhance structural strength, then strength is improved, but weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The cross member utilizes composite construction combining aluminum alloy material with structural inserts made of steel, carbon fiber, or other high-strength materials. This composite approach allows the base structure to be lightweight while strategic insertions provide localized strength enhancement, achieving high structural strength without proportionally increasing overall weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Structural inserts are strategically positioned at specific locations along the cross member where strength is most needed, such as high-stress zones or attachment points. This localized reinforcement approach ensures that material is added only where necessary to improve strength, rather than uniformly throughout the entire structure, thereby minimizing weight increase.

Inventive Principle:

Principle #3Local quality

2Stability of the object's composition

If structural inserts are added inside the cross member, then rigidity is improved, but device complexity increases

Engineering Contradiction:

Improvestructural rigidityVSAvoidstructural complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The cross member is divided into segments or zones, with structural inserts placed in specific segments rather than throughout the entire length. This segmentation allows rigidity to be improved in critical areas while keeping other areas simple and lightweight, thereby managing overall structural complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Structural inserts are nested inside the cross member structure, with inserts placed within the hollow or cavity spaces of the aluminum alloy cross member. This nested configuration allows the inserts to be integrated into the existing structure without requiring complete redesign, thus improving rigidity while limiting the increase in overall complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS20250276735A1Vehicle structural cross member

Publication Date: 2025.09.04 RIVIAN HOLDINGS LLC

AI summary

Apparatuses and methods for a vehicle structural elongated cross member are disclosed. An apparatus can include an elongated cross member. The apparatus can include a structural insert to disposed ins the elongated cross member. The apparatus can include a first sleeve configured to couple with a first end portion of the elongated cross member and to couple with a vehicle. The apparatus can include a second sleeve configured to couple with a second end portion of the elongated cross member and to couple with the vehicle.