Extruded Vehicle Beam With Localized Weak Zones
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Solution Overview
Problem
Existing side impact reinforcement beams for vehicles deform significantly at the point of impact, leading to substantial intrusions into the passenger compartment during side impacts, and their complex manufacturing processes require specialized tools.
Innovation Solution
A method for producing a reinforcing beam with zones of weakness by extruding a profile, cutting it into segments, and applying localized deformation through tearing or plastic deformation, which reduces bending resistance and simplifies the manufacturing process without needing complex tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If localized deformation is applied to create zones of weakness, then manufacturing complexity is reduced, but beam strength is compromised
Solution Approach 1:
The patent applies local quality by creating zones of weakness through localized deformation (tearing or plastic deformation) at specific positions along the beam. These zones have different mechanical properties (reduced bending resistance) compared to the rest of the beam, allowing controlled deformation at impact points while maintaining overall structural integrity. The deformation is localized to specific areas rather than affecting the entire beam structure.
2Object-affected harmful factors
If the beam is designed to deform at impact points, then passenger compartment intrusion is reduced, but manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-forming zones of weakness through localized deformation during the manufacturing process. These pre-created weak zones are designed to deform first during impact, guiding the beam's deformation behavior. The zones are prepared in advance with reduced bending resistance, so that during side impact, the beam bends at these predetermined locations rather than deforming uncontrollably, thereby reducing intrusion into the passenger compartment.
3Ease of manufacture
If zones of weakness are created by localized tearing, then manufacturing simplicity is improved, but beam rigidity is reduced
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and mechanical properties of specific zones through localized deformation. The tearing or plastic deformation process changes parameters such as wall thickness, material density, and structural integrity in the affected zones. This creates areas with reduced bending resistance while maintaining the overall beam structure. The parameter changes are localized and controlled, affecting only specific segments of the beam rather than the entire structure.
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 method allows for the creation of beams with reduced deflection and intrusions during side impacts, while simplifying the manufacturing process and minimizing scrap, resulting in a more efficient and cost-effective production of beams with enhanced passenger safety.
Implementation Method 1
a step of extruding a profile
Implementation Method 2
a step of localized deformation of the profile segment intended to create the zone or zones of weakness, characterized in that the step of localized deformation of the profile segment is carried out by localized tearing in one of the side walls of the beam
Data Source
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AI summary
Method for producing a reinforcement beam for a vehicle, comprising at least one weak zone arranged in such a way that the bending resistance of the beam is less in said weak zone than in the rest of the beam, characterised in that it comprises, in order, a step (A) of extruding a profile part, a step (B) of cutting the profile part so as to obtain at least one profile segment, a step (C) of locally deforming the segment of the profile part in order to create the weak zone or zones.