Door Beam Height Increase via Inverted Press-Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional door beams with aluminum alloy extruded members, when space between vehicle panels is limited, cannot increase height in the vehicle width direction, leading to reduced energy absorption during collisions.
Innovation Solution
A door beam with an aluminum alloy extruded member featuring a plastic worked part where the webs buckle outward, with the inner flange positioned closer to the outer flange side than originally, allowing for increased height and improved energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If press-forming is applied from outer flange side toward inner flange side, then the door beam can be manufactured with conventional methods, but the height in vehicle width direction cannot be increased when space between panels is limited
Solution Approach 1:
The patent applies press-forming from the inner flange side toward the outer flange side, reversing the conventional pressing direction. This inversion enables the webs to buckle outward and the inner flange to move toward the outer flange side, thereby increasing the height in the vehicle width direction while accommodating limited space between door panels
2Strength
If the door beam height in vehicle width direction is increased, then energy absorption during collision is improved, but the door beam cannot be stored in limited spaces between panels
Solution Approach 1:
The patent changes the press-forming direction parameter, which fundamentally alters the deformation behavior of the door beam. This parameter change enables the beam to achieve greater height and energy absorption capacity while the plastic worked part accommodates within limited storage space by positioning the inner flange closer to the outer flange side
3Strength
If press-forming is applied to increase door beam height, then energy absorption is enhanced, but the webs may buckle inward reducing structural integrity
Solution Approach 1:
By inverting the press-forming direction to press from the inner flange side toward the outer flange side, the patent ensures that the webs buckle outward rather than inward. This outward buckling maintains structural integrity while achieving the desired height increase and energy absorption enhancement
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
Enables the door beam to be stored in limited spaces while increasing its height in the vehicle width direction, enhancing energy absorption during collisions.
Implementation Method 1
a plastic worked part pressed in a height direction of the webs at an end in a longitudinal direction; the webs buckle outward at the plastic worked part
Data Source
AI summary
A door beam including an inner flange extending in a longitudinal direction, an outer flange extending in the longitudinal direction and facing the inner flange at a distance from the inner flange, and-a pair of webs connecting the inner flange and the outer flange. The inner flange has an end portion in the longitudinal direction which is made closer to an end portion of the outer flange such that the distance between the inner and outer flanges at the end portions is shorter than the distance at other portions of the inner and outer flanges.