Damper Housing Closed Cross Section Stiffness
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Solution Overview
Problem
Conventional damper housing structures with integral reinforcement portions formed by stamp forming lack adequate stiffness due to open cross sections, necessitating thicker materials and higher press forming pressures, increasing weight and manufacturing costs.
Innovation Solution
A vehicle body front structure with damper housing structures featuring closed cross sections for both the damper housing main body and reinforcement portions, eliminating the need for increased material thickness and reducing the requirement for high-pressure stamp forming, achieved through the use of extruded members and secure bonding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the sheet stock for the damper housing and reinforcement portions is increased to ensure adequate stiffness, then the mechanical strength is improved, but the weight of the damper housing structure increases
Solution Approach 1:
The patent applies curvature by forming the reinforcement portions with arcuate (curved) cross-sections instead of straight or angular shapes. This curved geometry provides higher moment of inertia and greater stiffness against bending forces, allowing the structure to achieve adequate mechanical strength with thinner sheet stock, thereby reducing weight without compromising structural integrity
Solution Approach 2:
The patent transitions from two-dimensional flat reinforcement shapes to three-dimensional curved cross-sectional forms. By adding the dimensional aspect of curvature to the reinforcement portion geometry, the structure achieves enhanced stiffness and strength characteristics without increasing material thickness, thus resolving the contradiction between strength and weight
2Strength
If the thickness of the sheet stock for the damper housing and reinforcement portions is increased to ensure adequate stiffness, then the mechanical strength is improved, but the pressure required for stamp forming increases
Solution Approach 1:
The curved cross-sectional geometry of the reinforcement portions reduces the forming pressure requirements during stamp forming. The arcuate shapes can be formed with lower pressing forces compared to flat or angular geometries, as the curved profile naturally distributes stress more evenly during forming, thereby avoiding the need for high-pressure equipment while still achieving adequate structural strength
Solution Approach 2:
The patent changes the geometric parameters of the reinforcement portions by adopting curved cross-sections instead of flat shapes. This parameter change in the cross-sectional geometry reduces the forming pressure required during stamp forming operations, allowing the use of lower-cost equipment while maintaining structural integrity through the curved design
3Stability of the object's composition
If thicker sheet stock is used for the damper housing and reinforcement portions, then adequate stiffness is achieved, but the cost of stamp forming machinery and dies increases
Solution Approach 1:
The curved cross-sectional design of the reinforcement portions provides adequate stiffness with thinner material, reducing the requirements for expensive high-pressure stamp forming equipment and costly stamp forming dies. The curved geometry can be formed using standard forming equipment at lower pressures, thereby reducing manufacturing costs while maintaining structural stability
Solution Approach 2:
By adding curvature as a third dimension to the reinforcement portion geometry, the structure achieves enhanced stiffness without requiring thicker materials or high-pressure forming equipment. This dimensional approach allows standard manufacturing equipment to produce the required structural integrity, reducing both capital equipment costs and operational expenses
Data Source
AI summary
In a vehicle front structure, without increasing the thickness of the material of a damper housing structure and reinforcement portions, an adequate mechanical strength in supporting the damper can be ensured, and the cost of the manufacturing facilities can be minimized. The damper housing structure is formed by a damper base, a damper housing main body, a front reinforcement portion and a rear reinforcement portion, and the damper base. Each of the damper housing main body, the front reinforcement portion and the rear reinforcement portion includes a closed cross section portion extending linearly with a same cross section.