Extruded Hollow Vehicle Header Beam with Stretch Bending
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vehicle header beams formed using stamped steel generate significant scrap material and have structural integrity issues due to multiple attachment features, making it difficult to use lightweight extruded metal while maintaining safety standards and reducing costs.
Innovation Solution
A method of forming a hollow header beam from an extruded member, cutting it to form a straight beam with a hollow interior, bending it to create a three-dimensional curvature, and attaching the end portions to A-pillars to span between them, while maintaining the end portions as generally straight to support the windshield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If stamped steel is used to form header beams, then consistent curvature can be achieved for attaching the windshield, but significant scrap material is generated
Solution Approach 1:
The patent changes the manufacturing process parameter from stamping to extrusion, and modifies the material form from solid to hollow. The hollow extruded beam is stretched during assembly to achieve the required curvature, transforming the forming mechanism while reducing material waste significantly.
2Adaptability or versatility
If multiple attachment features are added to header beams, then various components can be attached, but structural integrity is reduced
Solution Approach 1:
The patent segments the attachment features from the main beam structure by providing separate mounting brackets that attach to the hollow beam. This allows multiple attachment points without compromising the beam's structural integrity, as the brackets bear the attachment loads rather than the beam itself.
Solution Approach 2:
The mounting brackets are positioned within or alongside the hollow beam structure, nesting the attachment functionality within the beam's overall form. This integrates the attachment capability while maintaining the beam's strength.
3Weight of moving object
If lightweight extruded metal is used for header beams, then vehicle weight is reduced, but structural integrity is compromised due to difficulty in forming complex shapes
Solution Approach 1:
The patent utilizes the hollow beam structure as a flexible element that can be stretched and deformed into the required curved shape during assembly. The hollow cross-section provides structural strength while allowing plastic deformation to achieve the windshield curvature, combining lightweight properties with structural integrity.
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 approach reduces material waste, enhances structural integrity by minimizing structural discontinuities, and allows for the use of lightweight extruded metal while maintaining or reducing costs, aligning with safety standards and design requirements.
Implementation Method 1
The beam is stretched and bent to form a three-dimensional curvature in the beam between the opposing end portions
Data Source
AI summary
A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.