Solid-State Bonded Door Ring Reinforcement for Crash Load Paths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional frame members in vehicles face challenges in minimizing deformation during collisions while maintaining optimal weight and cost, often requiring increased sheet metal thickness or additional reinforcement pieces, which can elevate vehicle mass, reduce dynamic performance, and increase manufacturing costs.
Innovation Solution
A door ring assembly featuring frame members with solid-state bonded reinforcements, utilizing Ultrasonic Additive Manufacturing (UAM) to achieve optimal thickness and reduce the need for additional joining processes, thereby enhancing impact load paths and minimizing deformation without increasing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sheet metal thickness of frame members is increased to form an impact load path, then the strength and stiffness of the frame members are improved, but the vehicle mass increases and fuel economy deteriorates
Solution Approach 1:
The patent applies local quality by varying the sheet metal thickness only in specific areas where reinforcement is needed to form the impact load path, rather than uniformly increasing thickness throughout the entire frame member. This localized thickening provides the necessary strength and stiffness while minimizing the overall increase in vehicle mass.
2Strength
If the sheet metal thickness of frame members is increased to form an impact load path, then the strength and stiffness of the frame members are improved, but the amount of raw materials required increases and manufacturing cost increases
Solution Approach 1:
The patent uses local quality by concentrating the increased material thickness only in the specific regions required for impact load path formation, thereby reducing the total quantity of raw materials needed compared to a uniform thickness increase, while still achieving the necessary strength improvement.
3Strength
If reinforcement pieces are joined to frame members to locally increase strength and stiffness, then the structural integrity is improved, but additional consumable materials are required and manufacturing cost increases
Solution Approach 1:
The patent merges the reinforcement pieces with the frame member by forming them as a single integrated component through stamping and bonding processes. This eliminates the need for separate joining operations and reduces consumable materials such as welds, adhesives, or fasteners that would otherwise be required to attach reinforcement pieces to the frame members.
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 solution results in improved dynamic performance and fuel economy by optimizing frame member weight and reducing manufacturing costs through selective reinforcement placement, while ensuring minimal deformation in occupant spaces during collisions.
Implementation Method 1
solid-state bonded reinforcements, utilizing Ultrasonic Additive Manufacturing (UAM)
Data Source
AI summary
A door ring assembly is provided. The door ring assembly includes a frame member that includes a reinforcement. The reinforcement is solid-state bonded to the frame member. The frame member further includes a body and a first leg. The first leg extends outward from the body. Further, the first leg intersects with the body to form a corner radius, and the reinforcement is positioned on at least a portion of the corner radius.