Composite Tie Bar Assembly for Vehicle Frame Load Distribution
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Solution Overview
Problem
Current vehicle frame tie bar assemblies are heavy, complex, and costly due to multiple stamped metal components, which complicates load distribution and energy absorption during vehicle front impacts.
Innovation Solution
A tie bar assembly featuring molded composite shells supported by lateral reinforcement bars, with integral structural ribs and a crush can design, reduces weight and parts while effectively distributing loads and absorbing energy between side rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple stamped metal components are used in the tie bar assembly, then the structural strength and load distribution are improved, but the weight and complexity of the assembly increase
Solution Approach 1:
The patent combines multiple separate stamped metal components (tie bar, mounting brackets, reinforcement elements) into a single integrated molded composite component. This merging eliminates the need for multiple separate parts while maintaining the structural strength through the composite material's inherent properties and internal rib structures.
Solution Approach 2:
The patent uses molded composite materials to replace traditional stamped metal components. The composite material provides high strength-to-weight ratio, achieving the required structural strength while significantly reducing the overall weight of the tie bar assembly compared to all-metal constructions.
2Strength
If multiple stamped metal components are used in the tie bar assembly, then the structural strength and load distribution are improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent integrates multiple functional components (tie bar, mounting brackets, reinforcement elements) into a single molded composite part. This eliminates the need for separate manufacturing processes and assembly steps for multiple components, thereby reducing manufacturing complexity and assembly operations.
Solution Approach 2:
The single molded composite component performs multiple functions simultaneously: it acts as the tie bar, provides mounting brackets for bumpers and fog lamps, and includes internal reinforcement ribs for structural strength. This multi-functionality reduces the number of parts and simplifies the overall assembly.
3Weight of moving object
If a single molded composite shell is used instead of multiple metal components, then the weight and complexity are reduced, but the load distribution capability must be maintained
Solution Approach 1:
The molded composite shell incorporates locally optimized features including internal reinforcement ribs and varied wall thicknesses in specific areas. These local structural enhancements concentrate material where needed to handle load distribution requirements while keeping other areas lighter, maintaining overall load distribution capability with reduced weight.
Solution Approach 2:
The use of molded composite materials provides high strength-to-weight ratio and allows for complex internal structures to be integrated into the single component. The composite material's properties enable effective load distribution across the assembly while maintaining significantly lower weight compared to traditional metal constructions.
Data Source
AI summary
A composite tie bar assembly for distributing loads to a support frame of an automotive vehicle. The tie bar assembly includes a pair of spaced apart. reinforcement bars extending longitudinally between opposing ends. A tie bar shell is supported by the reinforcement bars and extends between opposite first and second distal cods. The tie bar shell has a first support plate extending between the reinforcement bars adjacent the first distal end and a second support plate extending between the reinforcement bars adjacent the second distal end. Bach of the support plates includes a plurality of structural ribs formed Integral therewith for distributing loads from the reinforcement bars to the support frame of the vehicle.