Vehicle Frame Rib Reinforcement via Local Thickness Variation
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Solution Overview
Problem
Conventional reinforcing structures for vehicle frame members made from resin or light metal materials, such as aluminum alloys, do not efficiently enhance the reinforcing effect while minimizing rib weight.
Innovation Solution
The structure incorporates standing wall and projecting portions with ribs that connect them, featuring portions of gradually changing thickness and height, along with specific curved and linear elements to reduce excess thickness and mitigate stress concentrations, thereby improving the reinforcing effect while reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional reinforcing ribs with uniform thickness are used, then the reinforcing effect is provided, but the rib weight becomes excessive and stress concentrations occur
Solution Approach 1:
The rib structure employs varying thickness distribution where the thickness is greater at the root portion (connected to the frame member) and gradually decreases toward the tip. This local quality variation optimizes the reinforcing effect at critical locations while reducing material usage and weight in less critical areas, resolving the contradiction between strength and weight.
Solution Approach 2:
The rib incorporates curved transition portions at the root end with specific curvature radii that are larger than those in conventional designs. These curved portions eliminate sharp corners and create smooth transitions, reducing stress concentrations while maintaining structural integrity and reinforcing effect, thereby reducing the need for excessive material.
2Strength
If rib thickness is increased to improve reinforcing effect, then strength is improved, but weight and material usage increase
Solution Approach 1:
Instead of uniformly increasing rib thickness throughout, the invention applies increased thickness selectively at the root portion where the reinforcing effect is most needed, while maintaining thinner sections toward the tip. This localized approach improves strength where required while minimizing material usage overall.
Solution Approach 2:
The rib design provides enhanced thickness and reinforcing effect only at the root portion (partial action) rather than throughout the entire rib length. This partial reinforcement is sufficient to achieve the desired reinforcing effect on the frame member without the excessive material usage that would result from uniform thickening.
3Ease of manufacture
If sharp corners are used at rib connections, then manufacturing is simpler, but stress concentrations occur reducing reliability
Solution Approach 1:
The rib design incorporates curved transition portions at the root end with optimized curvature radii that are larger than conventional designs. These curves eliminate sharp corners and create smooth transitions, significantly reducing stress concentrations and improving reliability under load, while still being manufacturable using standard molding processes.
4Ease of manufacture
If conventional curved portions with uniform curvature are used, then manufacturing is easier, but excess thickness remains increasing weight
Solution Approach 1:
The curved transition portions are designed with specific curvature radii that vary along the rib length, with larger radii at the root end and smaller radii toward the tip. This local variation in curvature optimizes the balance between stress reduction and material removal, eliminating excess thickness and reducing weight while maintaining manufacturability.
Data Source
AI summary
A reinforcing structure of a vehicle frame member includes: ribs that integrally connect standing wall portions, that are formed at a planar portion of a vehicle frame member, to one another, and that reinforce the planar portion; portions of gradually changing thickness that are formed at connected portions of the ribs with the standing wall portions; portions of gradually changing height that are formed at the connected portions of the ribs with the standing wall portions; first curved portions that are formed at the portions of gradually changing thickness; second curved portions that are formed at the portions of gradually changing thickness; third curved portions that are formed at the portions of gradually changing height; and fourth curved portions that are formed at the portions of gradually changing height.