Composite Trim Element Reducing Vehicle Weight and Assembly Complexity
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Solution Overview
Problem
Current motor vehicle body designs are heavy due to complex metallic structures, making it difficult to reduce weight while maintaining mechanical and acoustic stiffness, and existing solutions fail to minimize mass effectively while ensuring safety and assembly efficiency.
Innovation Solution
A trim element made of composite material, such as carbon fiber and epoxy resin, is used to form a monolithic part that extends from the bay upright to the center pillar and rear gutter of the vehicle, assembled using bonding glue to minimize bulk and provide structural reinforcement, while also serving as a decorative and shock-absorbing component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials and complex assembly connections are used, then mechanical strength and stiffness are ensured, but vehicle weight increases
Solution Approach 1:
The patent applies composite materials (specifically carbon fiber reinforced plastic) to replace traditional metallic materials in the trim element. This composite material provides equivalent or superior mechanical strength and stiffness while significantly reducing the weight of the component, directly addressing the contradiction between strength and weight.
2Reliability
If numerous metal parts and assembly connections are used, then structural integrity is maintained, but assembly complexity increases
Solution Approach 1:
The patent merges multiple separate metal parts and assembly connections into a single monolithic trim element made of composite material. This integration eliminates numerous welding, riveting, or clinching operations, simplifying the assembly process while maintaining structural integrity through the inherent properties of the composite material.
3Strength
If traditional metallic body structures are used, then mechanical resistance is ensured, but weight reduction is limited
Solution Approach 1:
The patent employs composite materials with high strength-to-weight ratio to replace traditional metallic body structures. The carbon fiber reinforced plastic provides equivalent mechanical resistance to steel while reducing the weight of the trim element by 40-50%, enabling significant vehicle weight reduction.
4Weight of moving object
If composite material is used for the trim element, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the vehicle body into distinct functional zones, applying composite material specifically to the trim element where weight reduction is most beneficial. This selective application allows the use of advanced manufacturing techniques for composites only where needed, while traditional methods continue for other components, balancing weight reduction with manufacturing feasibility.
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 use of composite materials reduces the vehicle's weight by 40-50% compared to steel, enhances structural stiffness, and simplifies assembly by reducing the number of parts, while providing improved safety and aesthetic appeal.
Implementation Method 1
the trim element is assembled to the body side via at least a second bead of bonding glue
Data Source
Figure 1~3
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Figure 7~8
AI summary
Trim element (11) for a motor vehicle which is integral, made of a composite material, and intended for being mounted on a surface of a body side facing the outside of the vehicle. The trim element is also designed to form a trim of a window post (2) of the motor vehicle and of at least one portion of a side roof rail of the motor vehicle forming an extension of the window post (2).