Composite Trailer Intrusion Guard With Replaceable Impact Bumper
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Solution Overview
Problem
Existing vehicle barrier structures, such as intrusion guards, are often heavy, costly, and difficult to manufacture, while also lacking sufficient structural integrity to withstand impacts without damage.
Innovation Solution
A lightweight composite intrusion guard structure featuring a reinforcing member with a support and an insert, mounted to a vehicle trailer without permanent attachment, and a replaceable bumper for enhanced impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional heavy materials such as metal are used to form intrusion guards, then structural strength and impact resistance are improved, but vehicle weight increases and manufacturing cost rises
Solution Approach 1:
The patent employs composite materials consisting of a thermoplastic matrix combined with reinforcement fibers (such as glass, carbon, or aramid fibers) to create an intrusion guard that achieves metal-level strength while significantly reducing weight. The composite structure provides both structural integrity and impact resistance without the excessive weight of conventional metal intrusion guards.
Solution Approach 2:
The patent utilizes thermoplastic materials that can change their mechanical properties through temperature variations. During normal operation, the material maintains rigid structural properties, but during impact events, the thermoplastic can undergo controlled deformation and energy absorption, then potentially recover or be replaced. This parameter-based approach allows the structure to adapt its response to different loading conditions.
2Strength
If conventional metal materials are used for intrusion guards, then structural integrity during impact is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The thermoplastic composite materials can be processed using injection molding or similar forming techniques that allow complex geometries to be manufactured in a single operation. The material's thermoplastic nature enables it to be heated, molded into the required intrusion guard shape with integrated features, and then cooled to set the final structure, significantly simplifying manufacturing compared to metal fabrication which may require multiple steps including cutting, welding, and assembly.
Solution Approach 2:
The patent integrates multiple functions into the intrusion guard structure through the molding process. The composite intrusion guard can be manufactured as a single integrated component that combines structural support elements, mounting features, and energy-absorbing characteristics, eliminating the need for separate manufacturing and assembly steps required for metal construction.
3Weight of moving object
If lightweight composite materials are used for intrusion guards, then vehicle weight is reduced, but structural support capability and impact resistance deteriorate
Solution Approach 1:
The patent uses fiber-reinforced thermoplastic composite materials where the reinforcement fibers (glass, carbon, or aramid) provide the structural strength and stiffness, while the thermoplastic matrix binds the fibers together and transfers loads between them. This composite architecture enables the intrusion guard to achieve high strength-to-weight ratio, providing sufficient structural support capability while maintaining lightweight characteristics.
Solution Approach 2:
The patent may employ varying fiber orientations, densities, or material compositions at different locations within the intrusion guard structure. Areas experiencing higher impact loads can be reinforced with higher fiber content or specific fiber orientations, while less critical areas use lighter construction, optimizing the overall structural support capability relative to the weight.
4Strength
If permanent attachment methods such as welding are used to mount intrusion guards, then structural connection strength is improved, but damage risk to the intrusion guard during removal and replacement increases
Solution Approach 1:
The patent designs the intrusion guard as a separable component that can be detached from the vehicle structure without permanent attachment. The connection system is divided into discrete mounting points or attachment mechanisms that allow the intrusion guard to be removed as a complete unit or in sections, facilitating easy replacement after impact damage without affecting the vehicle structure.
Solution Approach 2:
The patent introduces an intermediary mounting system between the intrusion guard and the vehicle structure. This intermediary connection mechanism (such as bolts, clips, or adhesive-mounted brackets) provides sufficient structural connection strength during normal operation and impact events, but allows for controlled detachment when removal is required, protecting both the intrusion guard and vehicle structure from damage.
Data Source
AI summary
An intrusion guard (20) for a trailer (12) of a vehicle ( ) 10, comprising: (a) a reinforcing member (22) adapted for connection to the trailer of the vehicle, wherein the reinforcing member includes a support (28) and an insert (26) positioned at least partially within the support; and (b) a bumper (36) connected to the reinforcing member.