Ductile UHSS Patch Vehicle Structural Member
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Structural members in vehicles face challenges in controlling deformation and energy absorption during compressive loads, particularly in crash scenarios, due to the limitations of Ultra High Strength Steels (UHSS) which offer high strength but low ductility and energy absorption.
Innovation Solution
A structural member configuration featuring a ductile main piece with a less ductile patch attached, where the patch is designed to crack under compressive loads, enhancing energy absorption and deformation control, while the ductile main piece maintains structural integrity. The patch can be made of hardened UHSS or martensitic steel, and its placement and geometry are optimized to manage deformation and energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Ultra High Strength Steel (UHSS) is used to increase strength, then strength is improved, but ductility and energy absorption deteriorate
Solution Approach 1:
The patent applies local quality by creating a dual-material structure where a UHSS patch is attached to a ductile main piece. The UHSS patch provides high strength and stiffness in critical areas, while the ductile main piece maintains overall formability and energy absorption. This spatial differentiation of material properties resolves the contradiction between strength and ductility by allowing each material to perform its optimal function in its designated region.
2Weight of moving object
If UHSS is used to reduce material thickness for weight savings, then weight is reduced, but energy absorption deteriorates
Solution Approach 1:
The patent employs composite materials by combining UHSS patch with ductile main piece in a hybrid structure. The UHSS enables thin-gauge construction for weight reduction, while the ductile base material compensates for the low energy absorption of UHSS. The composite system achieves both weight savings and adequate energy absorption by leveraging the complementary properties of the two materials working together.
3Strength
If hot forming is used to increase strength, then strength is improved, but ductility and energy absorption deteriorate
Solution Approach 1:
The patent applies segmentation by dividing the structural member into two functional segments: a hot-formed UHSS patch for strength and a cold-formed ductile main piece for energy absorption. This segmentation allows the hot forming process to be applied only to the patch area where high strength is critical, while the majority of the component retains ductile properties for energy absorption during deformation events.
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
This configuration improves the energy absorption and deformation predictability of structural members under compressive loads, enhancing passenger safety by tailoring the deformation behavior and increasing energy absorption capabilities.
Implementation Method 1
the patch is designed to crack under compressive loads, enhancing energy absorption and deformation control
Implementation Method 2
improves the energy absorption and deformation predictability of structural members under compressive loads
Data Source
AI summary
The present disclosure relates to structural members for a vehicle framework at least partially configured for supporting compressive loads. A structural member comprises a main piece and a patch. The main piece has a substantially U-shaped cross-section and comprises a bottom, a first side wall and a second side wall. The patch is attached to the main piece and comprises three patch portions: a bottom patch portion that extends over the bottom of the main piece, a first side wall patch portion that extends over the first side wall of the main piece, and a second side wall patch portion that extends over the second side wall of the main piece. The main piece is made of a more ductile material than the patch.