Continuous Composite Reinforcement for Vehicle Structural Energy Absorption
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Solution Overview
Problem
Designing a vehicle structure that effectively absorbs impact loads while maintaining weight and cost efficiency across various vehicle platforms, including electric, hybrid, and internal combustion engine vehicles, is challenging, especially in meeting durability and energy absorption requirements without significant changes to the body structure.
Innovation Solution
A hybrid structural assembly is introduced, featuring a vehicle structural member with a composite reinforcement member formed by a continuous method and cut to a predetermined length, which is attached between the ends of the structural member. This assembly includes a composite reinforcement member with a uniform or open cross-section, made of pultruded fibers and resin, and is designed to absorb energy during impacts by distributing loads along the length of the structural member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If composite reinforcement members are formed using traditional discrete methods, then manufacturing flexibility is improved, but manufacturing precision and structural consistency deteriorate
Solution Approach 1:
The composite reinforcement member is formed using a continuous pultrusion process where fibers and resin are continuously fed and cured through a die to create a uniform, consistent structure. This continuous manufacturing method eliminates the variability associated with discrete assembly methods while maintaining manufacturing efficiency.
Solution Approach 2:
The pultrusion process allows for precise control of material parameters including fiber orientation, resin distribution, and curing conditions. By controlling these parameters during continuous formation, the method achieves both manufacturing efficiency and high structural consistency with uniform mechanical properties throughout the reinforcement member.
2Strength
If vehicle structural members are designed with higher strength materials, then energy absorption capability is improved, but vehicle weight increases
Solution Approach 1:
The reinforcement member is constructed as a composite structure with a core component (such as foam or honeycomb) surrounded by a composite shell containing continuous fibers embedded in resin. This composite construction provides high strength-to-weight ratio, enabling effective energy absorption during impacts while minimizing the added weight compared to solid metal alternatives.
Solution Approach 2:
The composite reinforcement member features varying material distribution with higher fiber concentration and denser composite structure at critical stress zones (such as near attachment points and impact areas), while maintaining lower material density in less critical regions. This localized quality optimization maximizes energy absorption capability while minimizing overall weight.
3Manufacturing precision
If composite reinforcement members are formed by continuous methods and cut to length, then manufacturing precision and structural consistency are improved, but attachment complexity increases
Solution Approach 1:
The continuous composite reinforcement member is cut to predetermined lengths and configured as separate modular components that can be independently manufactured and then assembled to the vehicle structural member. This segmentation allows for precise manufacturing of individual pieces while simplifying the overall assembly process through standardized connection interfaces.
Solution Approach 2:
Connection features such as recesses, protrusions, or attachment surfaces are pre-formed as integral parts of the composite reinforcement member during the pultrusion process. This preliminary formation of connection features eliminates the need for post-manufacturing modification or complex assembly procedures, reducing attachment complexity while maintaining structural integrity.
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 hybrid structural assembly provides consistent and improved energy absorption characteristics, reducing movement and deformation of the vehicle structural member during impacts, while reducing overall vehicle weight and design complexity, and maintaining performance across different vehicle types.
Implementation Method 1
the composite reinforcement member being formed by a continuous method and cut to a predetermined length extending from the first end to the second end... designed to absorb energy during impacts by distributing loads along the length of the structural member
Implementation Method 2
This assembly includes a composite reinforcement member with a uniform or open cross-section, made of pultruded fibers and resin
Data Source
AI summary
A hybrid structural assembly includes a vehicle structural member extending from a first end to a second end, and a composite reinforcement member attached to the vehicle structural member between the first and second ends of the vehicle structural member. The composite reinforcement member being formed by a continuous method and cut to a predetermined length extending from the first end to the second end.