Extruded Hollow Vehicle Header Beam Attachment Design
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Solution Overview
Problem
Vehicle header beams made from lightweight extruded metal face challenges in maintaining structural integrity due to the need for attachment points, which can compromise their structural discontinuity and safety standards.
Innovation Solution
A method for forming a vehicle header beam involves extruding a hollow member with exterior and interior walls, bending it to create a curvature, and forming notches or protrusions in the exterior walls to separate load and attachment sections, allowing for attachment of subassemblies while minimizing strain and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If attachment points are added to the header beam for subassembly mounting, then the functionality and versatility of the vehicle frame is improved, but the structural integrity and safety standards deteriorate due to structural discontinuities
Solution Approach 1:
The header beam is divided into distinct load-bearing sections and attachment sections by interior walls. The load-bearing sections maintain continuous hollow extruded structure for strength, while attachment sections provide localized features for subassembly mounting. This segmentation allows different parts of the same component to serve different functions optimally.
Solution Approach 2:
Attachment features such as notches, protrusions, and formed surfaces are created only in specific localized areas of the header beam rather than throughout the entire structure. These local modifications provide attachment functionality while leaving the majority of the header beam structure intact and continuous for load-bearing purposes.
2Weight of moving object
If lightweight extruded metal is used for the header beam, then the weight of the vehicle is reduced, but the ability to provide attachment points without compromising structural integrity becomes more difficult
Solution Approach 1:
The lightweight extruded aluminum header beam is segmented into load-bearing sections with continuous hollow structure and attachment sections with localized features. This allows the overall structure to remain lightweight while providing necessary attachment points through strategic local modifications rather than adding heavy reinforcement throughout.
Solution Approach 2:
Attachment capabilities are provided through localized features (notches, protrusions, formed surfaces) in specific areas of the lightweight extruded beam, rather than requiring the entire beam to be designed for attachment purposes. This maintains the weight advantages of lightweight material while providing adequate attachment functionality where needed.
3Adaptability or versatility
If multiple attachment points are distributed along the header beam, then the versatility for subassembly mounting is improved, but the number of structural discontinuities increases reducing safety standards
Solution Approach 1:
Multiple attachment points are achieved by dividing the header beam into multiple attachment sections, each separated by load-bearing sections. The interior walls create distinct attachment zones where features like notches and protrusions can be located, allowing multiple subassemblies to be mounted while maintaining continuous load-bearing structure between attachment zones.
Solution Approach 2:
Each attachment point is created as a localized feature in a specific attachment section rather than as a disruption to the overall continuous structure. The load-bearing sections between attachment points maintain structural integrity, while the attachment sections provide localized functionality for mounting various subassemblies.
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
This approach enables the use of lightweight extruded metal header beams with reduced structural discontinuities, enhancing safety standards by distributing loads effectively and reducing strain, thus supporting the vehicle's structural integrity and weight reduction.
Implementation Method 1
bending the extruded hollow member to form a curvature
Data Source
AI summary
A frame component of a vehicle, such as a header beam that couples between the A-pillars of a vehicle frame, includes an extruded hollow member having top and bottom exterior walls and side walls that together enclose an elongated internal volume of the hollow member. A pair of interior walls extends along the internal volume separating outer load sections adjacent to the side walls from a central attachment section. The outer load sections are void of apertures for supporting continuous load paths. A formation on the bottom exterior wall protrudes into the internal volume in the central attachment section. The formation includes an inset surface angled, located, and otherwise configured for attaching a subassembly to the frame component.