Composite Reinforcement Frame for Vehicle Roof Openings
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Solution Overview
Problem
Existing reinforcement frames for vehicle roof openings are heavy, which negatively impacts fuel consumption due to their weight, while maintaining sufficient load capacity and strength.
Innovation Solution
A composite reinforcement frame with a layered structure consisting of two thin metal frame sheets and a lightweight plastic frame part, where the plastic core is surrounded by the metal sheets, providing high rigidity and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal frames are used for reinforcement, then high strength and rigidity are achieved, but the weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining metal frame sheets with a plastic foam core to create a hybrid structure that leverages the high strength of metal and the lightweight properties of plastic, achieving both structural integrity and weight reduction
Solution Approach 2:
The patent changes the parameter of material density by introducing a plastic foam core with lower density than solid metal, while compensating for strength through the layered composite structure and adhesive bonding
2Weight of moving object
If frame sheet thickness is reduced to lower weight, then weight decreases, but flexural rigidity and strength are compromised
Solution Approach 1:
The composite structure of thin metal sheets combined with plastic foam core provides enhanced flexural rigidity through the combination of materials with different mechanical properties, allowing thin sheets to maintain structural stability
Solution Approach 2:
The patent merges multiple thin metal frame sheets with a plastic core layer to create a composite structure where the combined assembly provides greater rigidity than individual thin sheets could achieve alone
3Weight of moving object
If lightweight plastic is used as the sole material, then weight is reduced, but load capacity and strength are insufficient
Solution Approach 1:
The patent creates a composite material system where plastic foam provides lightweight structure and metal frame sheets provide high-strength reinforcement, achieving both weight reduction and sufficient load capacity
Solution Approach 2:
The patent applies different materials to different regions of the frame structure - plastic foam in the core for weight reduction and metal sheets at the structural boundaries for strength and load-bearing capability
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a reinforcing frame (3), in particular for a roof opening (2) of a vehicle, comprising, in particular, a closed frame component (5) which closes an opening (4) and is designed as a composite component. According to the invention, the frame component (5) is made of a layer of two metal frame plates (10, 11), between which a plastic frame part (12) is mounted.