Vehicle Energy-Absorbing Core Assembly With Integrated Reinforcement
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Solution Overview
Problem
The complex relative positioning and machining of composite material and reinforcement parts in energy-absorbing devices for vehicles, such as motor vehicles, is challenging due to the need for precise alignment and adherence to deformation processes, which complicates the assembly and integration with plastic structures.
Innovation Solution
An energy-absorbing device comprising a core made of energy-absorbing material, a plastic structure, and a reinforcement part with mechanical retention elements that integrate the core and reinforcement part, allowing for a single-piece assembly that simplifies the manufacturing process and enhances impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite material and reinforcement part are positioned and assembled with precise alignment, then impact resistance is improved, but assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the composite material part and reinforcement part into a single integrated component. The reinforcement part is embedded within the composite material during molding, eliminating the need for separate positioning and assembly operations. This integration maintains the precise alignment required for impact resistance while significantly reducing assembly complexity.
Solution Approach 2:
The molded assembly serves multiple functions simultaneously: the composite material provides impact absorption, the reinforcement part enhances structural strength, and the integrated design itself acts as a positioning mechanism. This multi-functionality eliminates the need for separate positioning fixtures or assembly steps, reducing manufacturing complexity while maintaining strength.
2Manufacturing precision
If composite material and reinforcement part are joined with mechanical retention elements, then positioning precision is improved, but manufacturing process complexity increases
Solution Approach 1:
The reinforcement part is positioned and fixed within the composite material during the molding process itself, before any subsequent assembly operations. This preliminary action ensures precise positioning is achieved during the primary manufacturing step, eliminating the need for additional positioning operations or mechanical retention elements that would complicate the process.
Solution Approach 2:
The patent replaces mechanical retention elements (such as clips, fasteners, or adhesives) with a molded integration approach. The reinforcement part is mechanically locked within the composite material through the molding process itself, which provides precise positioning without requiring separate mechanical retention systems, thereby simplifying the overall manufacturing process.
3Ease of manufacture
If adhesive is used to join core and reinforcement part, then assembly is easier, but material compatibility and process flexibility are reduced
Solution Approach 1:
The patent replaces adhesive bonding with a molded integration system where the reinforcement part is mechanically embedded within the composite material during molding. This mechanical integration method is universally applicable to various materials (different composite materials and reinforcement types) without requiring specific adhesive formulations, thereby maintaining ease of manufacture while enhancing material compatibility and process flexibility.
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 facilitates the assembly of composite material and reinforcement parts, ensuring precise positioning and improved impact resistance without the need for material-specific adhesives, and adapts to various materials and deformation conditions.
Implementation Method 1
a plastic structure molded onto the core in order to form an assembly in a single piece
Implementation Method 2
at least one mechanical retention element contributing towards holding the core and the at least one reinforcement part together
Implementation Method 3
the core, composed of at least one energy-absorbing material... providing it with properties of resistance to impacts making it possible for it to absorb the energy in the event of an impact
Data Source
AI summary
An energy-absorbing device for a vehicle is disclosed. The vehicle includes at least one core, composted of at least one energy-absorbing material, and a plastic structure molded onto the core in order to form an assembly in a single piece. The device includes at least one reinforcement part forming a local additional thickness of the core. The device also includes at least one mechanical retention element contributing towards holding the core and the at least one reinforcement part together.