Hybrid Composite Lower Member for Automotive Weight and Safety
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Solution Overview
Problem
Current vehicle lower members either compromise on pedestrian safety or increase weight and manufacturing complexity, as they are either made of heavy metal or lightweight plastic, which fail to meet stringent safety and weight reduction requirements effectively.
Innovation Solution
A hybrid lower member is developed by over-molding plastic on metallic or composite tubes/channels with standard sections, providing a simplified manufacturing process, improved safety, and reduced weight by using a metallic/composite component that extends along the width of the plastic portion and is configured to attach to the vehicle's front end module with strengthening portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a pure plastic undertray is used, then weight is reduced, but pedestrian safety performance deteriorates
Solution Approach 1:
The patent applies composite materials by combining plastic and metal components in a hybrid undertray structure. The plastic portions provide weight reduction while metal components (such as metal channels or stamped metal pieces) provide the necessary strength and rigidity for pedestrian safety, achieving both weight reduction and maintained safety performance
2Reliability
If a steel spoiler is used, then pedestrian safety performance is improved, but weight increases
Solution Approach 1:
The patent replaces pure metal steel spoilers with a hybrid composite structure where metal components are strategically placed only where structurally necessary, combined with plastic portions. This reduces overall weight while maintaining the safety performance through optimized metal placement and hybrid construction
3Reliability
If a plastic undertray with numerous mounting locations is used, then pedestrian safety performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the undertray and spoiler functions into a single hybrid component structure. The metal components serve dual purposes as both structural elements for safety and as integrated mounting points, eliminating the need for separate brackets and reducing the number of discrete mounting locations while maintaining safety performance
Data Source
AI summary
A lower member device (420) and a method of constructing a lower member device includes arranging a metallic/composite (602) component in preparation for molding a plastic portion such that the metallic/composite component will extend along a width of the plastic portion. The lower member device and method further including configuring the metallic/composite component to attach to a front end module of a vehicle with attachment portions 606, molding the plastic portion over the metallic/composite component, and forming strengthening portions arranged adjacent the metallic/composite component in the plastic portion during molding.