Corrugated Tubular Reinforcement for Side-Impact Vehicle Frames
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Solution Overview
Problem
Existing vehicle frame structures face a compromise between weight, cost, and the need for both rigidity and controlled deformation during collisions, particularly in side impacts.
Innovation Solution
Incorporating a first tubular reinforcement member with annular ridges and grooves, forming a seamless oval or elliptic cross-section, which enhances deformation control while maintaining or improving rigidity and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a frame portion is made from metal plates or metal alloy plates formed into a requested shape, then strength and rigidity are improved, but weight and cost increase
Solution Approach 1:
The frame portion is divided into multiple components: first and second members forming a closed space, with a tubular reinforcement member inserted inside. This segmentation allows each component to be optimized independently - the members provide structural framework while the tubular reinforcement provides targeted strength enhancement with minimal material addition.
Solution Approach 2:
The tubular reinforcement member is nested inside the closed space formed by the first and second members. This nested configuration allows the reinforcement member to be contained within the existing structure, providing additional strength without significantly increasing external dimensions or overall weight.
2Stability of the object's composition
If a frame portion is designed to be rigid to receive impacts, then protection is improved, but ability to deform for absorbing impacts is reduced
Solution Approach 1:
The tubular reinforcement member is positioned specifically inside the closed space where impact absorption is needed. The reinforcement member itself has localized features (ridges and grooves) that provide different mechanical properties in different locations - rigid areas for protection and deformation zones for energy absorption.
Solution Approach 2:
The structure combines different material characteristics: the first and second members provide overall structural rigidity, while the tubular reinforcement member with its ridges and grooves provides controlled deformation capability. This composite structure allows simultaneous achievement of rigidity and deformation ability.
3Strength
If reinforcement is added to improve rigidity and prevent penetration, then protection is improved, but weight and cost increase
Solution Approach 1:
The tubular reinforcement member features dynamic geometric elements - ridges and grooves that can deform under impact loads. These dynamic features allow the structure to absorb impact energy through controlled deformation rather than rigid resistance, providing protection while minimizing material usage and weight.
Solution Approach 2:
The cross-sectional geometry of the tubular reinforcement member is optimized with specific ridge and groove configurations. These geometric parameter changes create a structure that provides maximum rigidity and protection with minimum material, as the ridges and grooves create efficient stress distribution patterns.
Data Source
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AI summary
A vehicle structure (100; 400; 500; 700; 800) comprising a portion (102; 402; 502; 702; 802) extending in a longitudinal direction (106), wherein the portion (102; 402; 502; 702; 802) comprises a first member (122) extending in the longitudinal direction (106) and a second member (124) extending in the longitudinal direction (106). The first member (122) is configured to face an inside (126) of a vehicle, and the second member (124) is configured to face an outside (128) of the vehicle. The first and second members (122, 124) are attached to one another to form a closed space (138) between them. The portion (102; 402; 502; 702; 802) comprises a corrugated first tubular reinforcement member (104; 604; 304; 702; 802) located in the closed space (138). The corrugations of the first tubular reinforcement member (104; 604; 304; 704; 804) comprise annular ridges (118; 618; 318; 828) and annular grooves (120; 620; 320; 820). At the outer surface (321; 821), each of the annular ridges (318; 818) has a recess (323; 823) at a first location (325; 825).