Composite Front End Carrier with Closed Box Sections
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Solution Overview
Problem
Conventional methods for supporting components at the front end of vehicles, particularly those with a 'body on frame' design, lack the necessary strength and rigidity for high-load applications and do not meet stringent impact requirements.
Innovation Solution
A carrier system featuring an upper and lower closed box section cross-members connected to a composite integration panel, providing enhanced strength and adaptability through forming processes and thermoplastic material usage, allowing for secure attachment of various vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stamped steel box sections in conjunction with plastic are used to produce the front end structure, then design flexibility is improved, but structural strength for high load applications deteriorates
Solution Approach 1:
The patent merges a steel box section with a plastic integration panel into a single composite structure. The steel cross-members provide structural strength while the plastic panel provides design flexibility and component integration features, resolving the contradiction between strength and flexibility by combining materials with complementary properties.
Solution Approach 2:
The invention uses a composite structure consisting of steel box sections and plastic materials bonded together. This composite approach allows the structure to simultaneously achieve the high strength of steel and the design flexibility of plastic, directly addressing the technical contradiction between structural strength and design adaptability.
2Ease of manufacture
If conventional stamped steel box sections are used, then ease of manufacture is improved, but ability to meet impact requirements and load requirements deteriorates
Solution Approach 1:
The composite structure of steel box sections bonded to plastic panels maintains the manufacturing simplicity of conventional stamped steel while significantly improving impact resistance and load-bearing capacity through the combined properties of both materials.
Solution Approach 2:
By merging the conventional steel box section structure with plastic integration panels, the invention retains the ease of manufacturing steel components while adding the strength and rigidity needed to meet impact requirements through the bonded composite structure.
Data Source
AI summary
A carrier for improving the strength of the front end of a vehicle, the carrier having an upper cross member which incorporates a closed box section, a composite integration panel connected to the upper cross member, and a lower cross member which also has a closed box section and is also connected to the composite integration panel. The closed box section of the upper cross member, and the closed box section of the lower cross member allow the component integration panel to be attached to the front end of a motor vehicle for supporting various vehicle components. The carrier improves strength and rigidity, as well as provides support for any particular vehicle component which needs to be attached to the front end.