Composite Door Impact Beam for Controlled Buckling Strength
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Solution Overview
Problem
Existing door impact beams struggle to provide sufficient buckling strength and deformation reduction in both barrier and pole side collisions, particularly when a large collision load is locally applied.
Innovation Solution
A door impact beam formed by a sheet-metal composite with a top plate, recessed bead, and walls, where the top plate faces the outer panel and the walls protrude from both ends, incorporating a reinforcing sheet metal to enhance structural integrity and absorb collision loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a door impact beam with multiple beads is used to increase buckling strength, then the buckling strength is improved, but the device complexity increases
Solution Approach 1:
The door impact beam is divided into multiple bead sections along its length, with each bead acting as an independent reinforcement element. This segmentation allows the beam to achieve high buckling strength through multiple small features rather than one complex feature, resolving the contradiction between strength and complexity.
Solution Approach 2:
The bead parameters (depth, spacing, cross-sectional shape) are optimized to achieve the required buckling strength. By adjusting these parameters, the beam achieves high strength with a relatively simple repetitive structure, rather than requiring a complex single-feature design.
2Strength
If a door impact beam with wide area load dispersion is designed, then the collision load absorption is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The load dispersion function is achieved through multiple segmented beads distributed along the beam length, rather than requiring a single complex wide-area feature. This segmentation simplifies the forming process for each individual bead while achieving cumulative load dispersion across the entire beam.
Solution Approach 2:
The bead spacing and dimensions are optimized to achieve effective load dispersion. By controlling these parameters, the beam achieves wide-area load absorption through a series of simpler, more manufacturable features rather than requiring high-precision single-feature forming.
Data Source
AI summary
A door impact beam includes a top plate, a recessed bead, and walls. The top plate faces an outer panel that constitutes a door of the vehicle and extends in the front-rear direction of the vehicle. The recessed bead is disposed on the top plate and has a U shape toward an inner panel that constitutes the door of the vehicle. The walls protrude toward the inner panel from both ends of the top plate in a width direction of the top plate. The door impact beam is formed by press-molding a sheet-metal composite. The sheet-metal composite includes a sheet-metal main body and a reinforcing sheet metal overlapping with a part of the sheet-metal main body in a longitudinal direction. The door impact beam extends in a front-rear direction of the vehicle in an internal space formed by the outer panel and the inner panel.