Fiber-Plastic Composite Reinforcing Element for Vehicle Body Impact Protection
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Solution Overview
Problem
Current vehicle body reinforcement methods, such as using high-strength steel cores or glass fiber thermoplastics, are costly and heavy, failing to meet stringent impact protection requirements while being inefficient in absorbing static forces and providing adequate reinforcement for vehicle body parts.
Innovation Solution
A fiber/plastics composite impact protection reinforcing element is designed to conform to vehicle body part contours, providing extensive contact and firm connection, increasing buckling resistance and strength while being lightweight and cost-effective, with options for form-fitting and adhesive bonding, and incorporating features like textured elements for enhanced strength and mechanical attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength press-hardened steel core is used to reinforce vehicle body parts, then buckling resistance and strength are improved, but weight and production costs increase
Solution Approach 1:
The patent uses fiber-reinforced plastic composite materials (such as glass fiber, carbon fiber, or aramid fiber reinforced plastics) to manufacture the impact protection reinforcing element. These composite materials provide high strength-to-weight ratio, achieving the required buckling resistance and strength while significantly reducing weight compared to traditional high-strength steel cores.
2Strength
If high-strength press-hardened steel core is used to reinforce vehicle body parts, then buckling resistance and strength are improved, but production costs increase
Solution Approach 1:
The patent employs fiber-reinforced plastic composite materials that can be manufactured using cost-effective processes such as resin transfer molding (RTM) or injection molding. These manufacturing methods are particularly advantageous for low-volume production, reducing tooling costs and plant investment compared to steel core production, while achieving the required structural strength.
3Object-affected harmful factors
If glass fiber thermoplastics are used for impact protection, then impact absorption is improved, but static load-bearing capacity and vehicle body support are reduced
Solution Approach 1:
The patent specifies that the fiber-reinforced plastic should have a fiber content of at least 30% by weight, preferably at least 40%, and most preferably at least 50%. This high fiber content significantly enhances the static load-bearing capacity and structural support properties while maintaining excellent impact absorption capabilities, thereby resolving the contradiction between impact protection and static strength.
4Strength
If reinforcing plates are used to reinforce vehicle body parts, then strength is improved, but manufacturing complexity and welding requirements increase
Solution Approach 1:
The patent integrates the impact protection reinforcing element directly into the vehicle body part structure during the molding process. The reinforcing element is formed as an integral part of the composite structure, eliminating the need for separate welding operations or complex assembly steps required when using traditional metal reinforcing plates.
Data Source
AI summary
An impact protection reinforcing element has at least one outer surface which is conformed to the contour of a surface of at least one vehicle body part in such a way that it may be positioned with extensive contact against the body part in the area of complementary construction and connected firmly to the body part. Provision is made for the impact protection reinforcing element to be formed of a fiber/plastics composite. A method of producing the impact protection reinforcing element uses an injection molding process.