Fiber-Reinforced Cross Car Beam With Integrated Crash Energy Absorption
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Solution Overview
Problem
Existing vehicle cockpit cross beams made of metal components are heavy, require multiple assembly steps, and have high CO2 usage during production and use, necessitating a more efficient and lightweight alternative.
Innovation Solution
A cross car beam manufactured entirely from fiber-reinforced polymer with a u-shaped cross-section, incorporating deformable crash pads and collapsible guiding elements to absorb impact energy, reducing the number of components and enabling a system-integrated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used for cross car beam, then mechanical strength is improved, but weight increases and CO2 usage during production increases
Solution Approach 1:
The patent applies composite materials by using fiber-reinforced polymer instead of traditional metal components. The fiber reinforcement provides the necessary mechanical strength while the polymer matrix reduces weight compared to steel or aluminum, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent changes the material parameters by transitioning from metallic materials to polymer-based composite materials. This parameter change enables achieving comparable mechanical strength through fiber reinforcement while significantly reducing density and weight.
2Strength
If metal components are used for cross car beam, then mechanical strength is improved, but device complexity increases due to multiple assembly steps
Solution Approach 1:
The patent merges multiple components into a single integrated cross car beam structure. The fiber-reinforced polymer can be molded as one piece, eliminating the need for assembling multiple metal components, welds, or fasteners, thus reducing device complexity while maintaining strength.
Solution Approach 2:
The patent applies local quality by strategically orienting fibers in the polymer matrix to provide strength exactly where needed in the cross car beam structure. This localized reinforcement allows the use of lighter materials overall while maintaining required mechanical properties.
3Strength
If metal components are used for cross car beam, then mechanical strength is improved, but ease of manufacture deteriorates due to high installation effort
Solution Approach 1:
The patent combines the cross car beam into a single integrated component that can be installed as one unit rather than assembling multiple metal parts. This significantly reduces installation effort and time while the fiber reinforcement maintains the necessary strength.
4Weight of moving object
If fiber reinforced polymer is used for cross car beam, then weight is reduced and CO2 usage is reduced, but mechanical strength may deteriorate
Solution Approach 1:
The patent uses composite materials where fibers (such as glass or carbon fibers) are embedded in a polymer matrix. The fibers provide the necessary mechanical strength while the polymer reduces weight, achieving both goals simultaneously rather than trading one for the other.
Solution Approach 2:
The patent applies local quality by strategically orienting and distributing fibers within the polymer matrix to provide strength exactly where mechanical loads are applied, allowing weight reduction in non-critical areas while maintaining strength where needed.
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 fiber-reinforced polymer cross car beam achieves reduced weight and CO2 emissions by integrating multiple functions into a single component, providing effective force absorption and impact energy management without the need for additional assembly steps.
Implementation Method 1
The fibers include glass fibers or carbon fibers whose orientation in the polymer is aligned with the force flow through the cross car beam
Implementation Method 2
the at least one deformable crash pad is adapted to absorb impact energy, such as the impact energy of a body from the passenger compartment
Implementation Method 3
the collapsible guiding element includes a guiding surface adapted to guide the crash pad during deformation
Data Source
AI summary
The present disclosure relates to a cross car beam for a vehicle, the cross car beam including a first main body extending in a longitudinal direction from a first end to a second end. The first main body has a u-shaped cross section following the longitudinal direction. The cross car beam is formed integrally by at least one fiber reinforced polymer.