Composite Rollover Structure With Locking Joints for Load Robustness
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Solution Overview
Problem
Existing rollover devices for passenger compartments of motor vehicles are either too heavy or lack the necessary robustness against various directional forces, and they often require torque-resistant connections that are not weight-optimized.
Innovation Solution
A rollover device comprising struts made of fiber-reinforced plastic and metallic fastening feet, where the fastening feet are connected to the struts via both material-locking and form-locking connections, enabling a lightweight yet robust design capable of withstanding vertical, transverse, and longitudinal forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for struts, then robustness against forces is improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining fiber-reinforced plastic struts with metallic fastening feet. The fiber-reinforced plastic provides sufficient strength-to-weight ratio for the strut structure, while the metallic fastening feet provide robust connection capability. This composite approach resolves the contradiction by using each material where it excels: fiber-reinforced plastic for weight optimization and metallic material for connection robustness.
2Weight of moving object
If fiber-reinforced plastic is used for fastening feet, then weight is reduced, but robustness against high local surface pressures and shear or bending stresses deteriorates
Solution Approach 1:
The patent applies local quality by using different materials for different parts of the fastening system. The struts are made of fiber-reinforced plastic where weight optimization is paramount, while the fastening feet are made of metallic material where high local surface pressures and shear or bending stresses occur. This localized material selection resolves the contradiction by matching material properties to specific functional requirements.
3Strength
If torque-resistant connections are used for mounting, then robustness against longitudinal forces is improved, but weight increases
Solution Approach 1:
The patent applies segmentation by separating the mounting function into distinct metallic fastening feet that are optimized for torque-resistant connections. This allows the strut structure itself to remain lightweight (fiber-reinforced plastic) while the connection elements (metallic fastening feet) provide the necessary torque resistance. The segmentation of functions resolves the contradiction by isolating the weight-critical structure from the connection-critical elements.
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 solution achieves a weight-optimized design while ensuring robustness against various directional forces, allowing for efficient load distribution and secure mounting on the vehicle body, even under tensile stress.
Implementation Method 1
The adhesive bond (41) connects the metallic fastening foot (36, 37) to the corresponding strut end (34, 35) in a material-locking manner
Implementation Method 2
The form-locking connection is configured in the overlap region (38) and is implemented in a torque-resistant manner
Data Source
AI summary
A rollover device for a passenger compartment of a motor vehicle includes a plurality of struts made of fiber-reinforced plastic, and a plurality of fastening feet made of metallic material for connecting the rollover device to a vehicle body. At least one fastening foot made of metallic material is connected to a respective strut made of fiber-reinforced plastic via a material-locking connection on the one hand and via a form-locking connection on the other hand.