Door Beam Weight Reduction via Local Quality and Dynamics
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Solution Overview
Problem
Conventional door beams that reinforce vehicle doors with a closed cross section effectively absorb impact energy but result in increased weight.
Innovation Solution
A door beam design with an open cross section, featuring upper and lower inner flanges and an outer flange, where the outer flange is thicker than the inner flanges, and the ribs' thickness gradually increases towards the inner flanges, reducing weight while maintaining impact energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed cross section is used to ensure impact energy absorption, then the amount of absorption of impact energy is ensured, but the door beam increases in weight
Solution Approach 1:
The patent applies local quality by varying the thickness of different components: the outer flange has a larger thickness than the inner flanges, and the ribs have gradually increasing thickness from the outer flange toward the inner flanges. This localized thickness distribution optimizes impact energy absorption in critical areas while reducing weight in less critical areas, resolving the contradiction between reliability and weight.
2Reliability
If the thickness of the outer flange is made larger than the inner flanges, then impact energy absorption is improved, but the weight increases
Solution Approach 1:
The outer flange is designed with a larger thickness than the inner flanges to provide superior impact energy absorption capability where it is most needed. This localized thickness enhancement improves reliability without requiring the entire structure to be uniformly thick, thereby controlling overall weight increase.
Solution Approach 2:
The ribs are designed with gradually increasing thickness from the outer flange toward the inner flanges, creating a dynamic thickness profile that optimizes structural performance. This gradual transition provides enhanced impact resistance near the outer flange while progressively reducing material usage toward the inner flanges, balancing reliability and weight.
3Ease of manufacture
If the ribs have uniform thickness, then manufacturing is simplified, but deformation resistance under impact is reduced
Solution Approach 1:
The ribs are designed with non-uniform thickness, featuring gradually increasing thickness from the outer flange toward the inner flanges. This local quality variation enhances deformation resistance in regions experiencing higher stress during impact while maintaining manufacturability through a systematic thickness gradient that can be achieved through conventional forming processes.
Data Source
AI summary
A door beam includes: an upper inner flange; a lower inner flange; an outer flange; an upper rib; and a lower rib. A thickness of the outer flange is larger than a thickness of the upper inner flange and a thickness of the lower inner flange. A thickness of the upper rib becomes gradually larger from the outer flange toward the upper inner flange, and a thickness of the lower rib becomes gradually larger from the outer flange toward the lower inner flange.