Door Impact Beam Reinforcement for Bending Strength
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Solution Overview
Problem
The existing door impact beams, particularly those with a W-shaped cross section, suffer from reduced section modulus and strength when subjected to bending moments due to easy unfolding of side edges, leading to decreased support load during vehicle collisions.
Innovation Solution
A door impact beam design featuring a reinforcement portion with a W-shaped cross section, having a width greater than the beam body, with curved streamlined edges and beads, and grooves to enhance the cross-sectional area and prevent collapse, integrated into the beam body to increase strength and support load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a W-shaped cross section is used for cold press forming, then productivity and production cost are improved, but section modulus and strength are reduced when bending moment is applied
Solution Approach 1:
The patent applies local quality by adding a reinforcement portion with different geometric properties (greater width, curved streamlined edges, beads, and grooves) at the central web region of the door impact beam. This localized structural enhancement increases the section modulus and bending strength specifically where needed, while maintaining the overall W-shaped cross section for cold press forming compatibility. The reinforcement portion has a width greater than the beam body width, creating a local quality difference that addresses the strength deficiency without changing the entire structure.
2Ease of manufacture
If side edges are made simple W-shaped, then manufacturing is easier, but edges unfold easily under bending moment reducing support load
Solution Approach 1:
The patent applies spheroidality by replacing the straight edges of the W-shaped cross section with curved streamlined edges in the reinforcement portion. The first and second edges are formed with curvature that follows a streamlined shape, which prevents easy unfolding under bending moments. The curved geometry provides better structural stability and resistance to deformation while still being compatible with cold press forming manufacturing processes.
Solution Approach 2:
The patent applies parameter changes by modifying the geometric parameters of the reinforcement portion, specifically adding beads and grooves that create local variations in thickness and stiffness. These parameter changes (bead height, groove depth, curvature radius) enhance the edge stability and prevent unfolding under bending loads, while maintaining manufacturability through cold press forming.
3Strength
If reinforcement portion is added with greater width, then section modulus and strength are increased, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating the reinforcement portion as a continuous extension of the central web, with the first and second edges continuously connected to the inner and outer sidewalls. This merging approach creates a unified structural element that increases strength without requiring separate components or complex assembly operations. The reinforcement portion is formed as an integral part of the door impact beam through cold press forming, reducing overall device complexity.
Solution Approach 2:
The reinforcement portion serves multiple functions simultaneously: it increases the section modulus, provides edge stability through curved streamlined edges, prevents unfolding under bending moments, and maintains compatibility with cold press forming manufacturing. This multi-functionality reduces the need for additional separate components, thereby managing device complexity while achieving enhanced strength and reliability.
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
The enhanced cross-sectional area and strength of the door impact beam improve its resistance to bending moments, increasing support load and reducing the likelihood of collapse during side impacts, while also reducing manufacturing costs and weight.
Implementation Method 1
a press type door impact beam is produced by forming a cold-rolled steel sheet using a cold press forming method
Implementation Method 2
since a steel sheet having a high yield strength (e.g., 1180 MPa or higher) is subject to constraint conditions for cold press forming due to a strong spring-back phenomenon during the cold press forming
Data Source
AI summary
A door impact beam is provided. The beam includes a beam body that has a W-shaped cross section and a reinforcement portion. The reinforcement portion is disposed in middle of the beam body and has a width greater than that of the beam body. Additionally, the reinforcement portion has first and second edges that are symmetrically convex with respect to a central axis of the beam body and the first and second edges have a curved streamlined shape.