Composite Vehicle Frame with Honeycomb Core
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Solution Overview
Problem
Traditional land vehicle frames made of steel are heavy, costly, and inefficient, with existing composite structures failing to provide a lightweight, strong, and cost-effective alternative that does not rely on external frames.
Innovation Solution
A composite vehicle frame is constructed by bonding carbon-fiber-epoxy or fiberglass-epoxy panels with a lightweight separator material like honeycomb, interposed with stringers to distribute loads and enhance rigidity, eliminating the need for a traditional rail frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional steel rail frame is used, then strength and rigidity are improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent applies composite materials by bonding carbon-fiber-epoxy or fiberglass-epoxy panels with lightweight separator material like honeycomb to create a frame structure that achieves high strength-to-weight ratio, eliminating the need for traditional heavy steel rails while maintaining structural integrity
Solution Approach 2:
The frame is segmented into multiple composite panels bonded together with separator material, creating a modular structure that distributes loads efficiently across discrete components rather than relying on a continuous heavy steel framework
2Stability of the object's composition
If cross members are added to enhance rigidity, then structural strength is improved, but air resistance and weight increase
Solution Approach 1:
The patent uses thin composite panels with honeycomb separator material that provide structural rigidity through their layered construction and geometric configuration, eliminating the need for protruding cross members that would increase air resistance
Solution Approach 2:
The frame structure transitions from a three-dimensional framework with cross members to a two-dimensional panel-based construction that achieves rigidity through in-plane structural design, reducing aerodynamic drag
3Strength
If steel is used for frame construction, then a strong platform is provided, but cost and weight increase
Solution Approach 1:
The patent replaces expensive steel with composite materials made from carbon fiber or fiberglass reinforced with epoxy resin, bonded to lightweight separator material, achieving comparable or superior strength at lower cost and weight
Solution Approach 2:
The invention changes the material parameters from metallic steel to polymer-matrix composites, fundamentally altering the strength-to-cost and strength-to-weight ratios in favor of the composite construction
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 frame achieves increased safety, reduced weight, and lower manufacturing costs while maintaining structural integrity and versatility, enabling efficient use of alternative energy sources and safer battery placement.
Implementation Method 1
bonding carbon-fiber-epoxy or fiberglass-epoxy panels with a lightweight separator material like honeycomb
Data Source
AI summary
A composite frame for vehicles formed with a honeycomb or similar core laminated on the top and bottom sides with a layer of material joined by an adhesive layer. One or more structural beams or stringer are interposed between the top and bottom layer of the composite frame running part or all of the length or width of the composite frame. Each of these structural members may also be joined to the top and bottom material as well as the adjacent honeycomb or by a layer of adhesive or by other means. One embodiment of the frame may be perfectly flat along a horizontal axis. A second embodiment may conform to any curvature, angle or combination specified.