Vehicle Frame Hollow Cavity Reinforcement System
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Solution Overview
Problem
Hollow cavities in vehicle frames reduce strength, increase noise, and vibration, while existing reinforcements may not adequately address these issues across various load directions and deformation concerns.
Innovation Solution
A structural reinforcement system comprising a rigid carrier with a bonding material and an insert, designed to enhance structural rigidity by providing primary reinforcement and addressing specific load directions and deformation issues through customizable configurations and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If hollow cavities are introduced into vehicle frames, then weight and material costs are reduced, but structural strength and rigidity are compromised
Solution Approach 1:
The patent employs a composite reinforcement system combining a rigid carrier (providing structural framework), expandable foam bonding material (providing adhesive and dampening properties), and an insert (providing additional structural support). This composite approach allows the hollow cavity to maintain reduced weight while achieving enhanced structural strength through the combination of multiple materials with complementary properties.
2Loss of substance
If hollow cavities are introduced into vehicle frames, then material costs are reduced, but noise and vibration increase
Solution Approach 1:
The patent converts the harmful noise and vibration effects into beneficial dampening by using the expandable foam bonding material as a noise and vibration dampener. The foam, when expanded, fills the cavity space and provides acoustic and vibration dampening properties, transforming the previously harmful hollow cavity into a beneficial noise-reducing feature while still maintaining material cost efficiency.
3Strength
If traditional reinforcements are used in hollow cavities, then some structural support is provided, but adequate reinforcement across various load directions is not achieved
Solution Approach 1:
The patent creates a universal reinforcement system where the rigid carrier provides primary structural support, the expandable foam provides both bonding and multi-directional dampening, and the insert provides additional structural reinforcement. This multi-functional system addresses various load directions and deformation concerns simultaneously, making the reinforcement adaptable to different loading scenarios without requiring multiple separate reinforcement components.
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 system effectively increases the structural rigidity of hollow cavities in vehicle frames, reducing deformation and noise while maintaining lightweight construction, by using a combination of a rigid carrier and insert with a bonding material that secures the assembly in place.
Implementation Method 1
The foam expands during the manufacturing process, securing the rigid carrier in place as the foam contacts the walls of the hollow cavity
Implementation Method 2
a bonding material, such as an expandable foam, which is applied to a rigid carrier. The foam expands during the manufacturing process, securing the rigid carrier in place as the foam contacts the walls of the hollow cavity
Data Source
Figure 1
Figure 2~3
Figure 4A~6B
AI summary
Disclosed are various embodiments of a structural reinforcement system (20). The system reinforces hollow cavities within various products to increase the structural rigidity of the product. The system generally includes a rigid carrier (22), a bonding material (40), and an insert (30). The rigid carrier provides the primary structural reinforcement within the cavity, and also serves as a substrate to carry the bonding material. The insert is provided to increase the structural rigidity of the reinforcement system.