Fiber-Reinforced Plastic Vehicle Body With Ductile Deformation Element
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Solution Overview
Problem
Fiber-reinforced plastic vehicle body components, such as sill profiles, are prone to breaking or splintering under high forces and have a limited elastic range, while foam-filled alternatives are dense and inefficient, necessitating a solution for enhanced energy absorption and deformation in vehicle collisions.
Innovation Solution
Integration of a ductile deformation element, potentially with a honeycomb structure, made of plastic or metal, positioned in front of or behind the body component to absorb forces before transferring them to the body component, allowing for targeted deformation and easy attachment, repair, and reduced corrosion risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If foam is used to fill sill profiles for energy absorption, then energy absorption capability is improved, but density increases and manufacturing complexity increases
Solution Approach 1:
The patent employs a foam material with controlled porosity to fill the deformation element. The foam structure provides high energy absorption capability through cell collapse mechanisms while maintaining relatively low density. The porous structure allows the material to deform progressively under impact loads, absorbing energy efficiently without requiring high material density.
Solution Approach 2:
The invention creates a composite structure by combining the fiber-reinforced plastic deformation element with the foam filler. This composite construction integrates the high strength and ductility of the thermoplastic material with the energy-absorbing characteristics of the foam, achieving optimal performance in both structural integrity and energy absorption while controlling overall density.
2Force
If deformation elements are integrated into the center of body components, then force distribution is improved, but manufacturing complexity increases and repair difficulty increases
Solution Approach 1:
The patent separates the deformation element from the main body component, positioning it at the front end as a distinct module. This segmentation allows the deformation element to be designed, manufactured, and installed independently, simplifying the overall manufacturing process while still achieving effective force distribution during impact through its strategic positioning in the load path.
Solution Approach 2:
The deformation element acts as an intermediary component between the external impact force and the main body component. It serves as a buffer that absorbs and distributes impact forces before they reach the critical structural elements, protecting the body component while maintaining relatively simple manufacturing and repair procedures.
3Weight of moving object
If fiber-reinforced plastic is used for body components, then weight is reduced, but ductility decreases and impact resistance decreases
Solution Approach 1:
The patent utilizes the temperature-dependent properties of thermoplastic materials. By heating the deformation element during installation, the material becomes more ductile and easier to form. After cooling, it regains its strength while maintaining the ability to deform plastically under impact loads. This parameter change allows the same material to provide both weight reduction and improved impact resistance.
Solution Approach 2:
The deformation element is designed as a sacrificial component that is intended to deform or fail during impact events, protecting the more critical body component. After an accident, the deformation element can be replaced without replacing the entire body structure, enabling cost-effective repair while maintaining the lightweight fiber-reinforced plastic construction.
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 ductile deformation element enables controlled plastic deformation of the vehicle body during collisions, enhancing energy absorption and force distribution, while being easy to manufacture, repair, and maintain, with minimal corrosion and cost.
Implementation Method 1
a deformation element, in particular ductile, is arranged in front of the body component in the main direction of travel of the vehicle
Implementation Method 2
the deformation element according to the invention is first subjected to compression before the force is transferred to the respective body component itself
Implementation Method 3
The deformation element is further designed with a honeycomb structure. Such a honeycomb structure can be advantageously manufactured from thermoplastic material using injection molding. It exhibits low density combined with high strength and high energy absorption during impact-induced deformation.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a body of a vehicle, comprising at least one body component made of fiber-reinforced plastic, wherein a deformation element is arranged in front of the body component in a main direction of travel of the vehicle. According to the invention, a deformation element is alternatively or additionally arranged behind the body component in a main direction of travel of the vehicle.