Vehicle structure having an optimized crash performance

Solution Overview

Problem

Current structural components for motor vehicles face challenges in achieving optimized crash behavior that balances high energy absorption with minimal space requirements, while also being cost-effective and easy to produce.

Innovation Solution

A structural component with a reinforcement layer made of fiber composite material featuring areas of different strength, achieved through a radiation-curable polymer matrix component, which is cured to create targeted weak points for energy dissipation during crashes, allowing for efficient energy absorption without buckling and reduced distortion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a structural component uses uniform reinforcement throughout, then manufacturing is simple and cost-effective, but crash energy absorption is insufficient in specific critical areas

Engineering Contradiction:

Improvecrash energy absorptionVSAvoidstructural uniformity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies local quality by creating a reinforcement layer with spatially varying fiber orientation angles. The fiber orientation angle varies continuously or discontinuously across different regions of the structural component, allowing specific areas to have enhanced crash energy absorption properties while other areas maintain simpler characteristics. This resolves the contradiction by providing localized strength enhancement without requiring complete structural redesign.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the orientation angle parameter of fibers in the reinforcement layer to optimize crash performance. By varying the fiber orientation angle across different regions, the component achieves optimized crash energy absorption in critical areas while maintaining manufacturing feasibility. This parameter variation allows tailored mechanical properties without fundamentally changing the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If the structural component is designed to buckle for energy absorption, then energy dissipation is achieved, but the component requires more space and may compromise structural integrity

Engineering Contradiction:

Improvecrash energy dissipationVSAvoidcomponent space requirement

Core Design Contradiction:

Loss of energyVSVolume of stationary object

Solution Approach 1:

The patent applies local quality by creating a reinforcement layer with spatially varying fiber orientation angles. The fiber orientation angle varies continuously or discontinuously across different regions of the structural component, allowing specific areas to have enhanced crash energy absorption properties while other areas maintain simpler characteristics. This resolves the contradiction by providing localized strength enhancement without requiring complete structural redesign.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses a composite reinforcement layer combining fibers with varying orientations bonded to the structural component. This composite structure enables controlled energy dissipation through fiber breakage and deformation in specific regions, achieving crash energy absorption without requiring excessive component volume or compromising overall structural integrity.

Inventive Principle:

Principle #40Composite materials

3Strength

If high-strength materials are used throughout the structural component, then strength and rigidity are improved, but cost increases and deformability in crash areas is reduced

Engineering Contradiction:

Improveoverall structural strengthVSAvoidmanufacturing cost and complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies local quality by creating a reinforcement layer with spatially varying fiber orientation angles. The fiber orientation angle varies continuously or discontinuously across different regions of the structural component, allowing specific areas to have enhanced crash energy absorption properties while other areas maintain simpler characteristics. This resolves the contradiction by providing localized strength enhancement without requiring complete structural redesign.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the orientation angle parameter of fibers in the reinforcement layer to optimize crash performance. By varying the fiber orientation angle across different regions, the component achieves optimized crash energy absorption in critical areas while maintaining manufacturing feasibility. This parameter variation allows tailored mechanical properties without fundamentally changing the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

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 solution enables significant energy dissipation in a compact form, minimizing residual stresses and distortion, while using inexpensive materials and allowing for quick production and adaptation, making it suitable for various vehicle components.

Implementation Method 1

a radiation-curable polymer matrix component, which is cured to create targeted weak points for energy dissipation during crashes

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentEP3648966B1Vehicle structure having an optimized crash performance

Publication Date: 2021.08.18 AUDI AG

Figure 1a~1b
Figure 2

AI summary

The invention relates to a motor vehicle body or chassis component having an improved crash performance as well as to a process for manufacturing a body or chassis component having an improved crash performance.