Hybrid Structural Part with Extruded Reinforcement Patch
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Solution Overview
Problem
Existing motor vehicle structural parts face a conflict between achieving torsion resistance, crash safety, and cost-effective production with optimized weight and strength, particularly in longitudinal directions, where extrusion technology limits cross-sectional geometry optimization.
Innovation Solution
A motor vehicle hybrid structural part comprising a main steel or light metal alloy sheet-metal structural part and an extruded light metal reinforcement patch with varying wall thickness, oriented at an angle of 70° to 110° relative to the main structural part's longitudinal direction, allowing for optimized cross-sectional design and weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extrusion technology is used to produce light metal structural parts, then production cost and manufacturing complexity are reduced, but the cross-sectional geometry optimization and longitudinal rigidity are limited
Solution Approach 1:
The patent combines extruded light metal profiles with additional reinforcement elements (such as welded-on plates, angles, or channels) to create a composite structural part. The extruded profile provides the basic structure and cost-effective production, while the added reinforcement elements enhance the longitudinal rigidity and strength without requiring complete redesign of the extrusion process
Solution Approach 2:
The structural part is divided into two functional segments: the extruded profile segment that provides the base structure and benefits from cost-effective extrusion manufacturing, and the reinforcement segment that is added separately to provide enhanced longitudinal strength. This segmentation allows each part to be optimized independently for its specific function
2Shape
If sheet-metal structural parts are used for motor vehicle body, then design flexibility and cross-sectional optimization are improved, but production cost and manufacturing complexity increase
Solution Approach 1:
Instead of producing the entire structural part as a complex sheet-metal component, the patent applies reinforcement elements only to specific regions where longitudinal strength is needed. The majority of the structure uses the simpler, more cost-effective extruded profile, with reinforcement added partially where required by structural analysis
3Strength
If reinforcement is added to extruded structural parts, then longitudinal strength is improved, but weight and manufacturing complexity increase
Solution Approach 1:
The reinforcement elements are strategically positioned only in regions where longitudinal strength is critically needed, such as connection zones or high-stress areas. The wall thickness and dimensions of reinforcement elements are locally optimized based on the specific loading conditions at each position, avoiding unnecessary weight addition in low-stress regions
Data Source
AI summary
Motor vehicle hybrid structural part, comprising a main structural part 2 and at least one reinforcement patch the main structural part 2 being embodied as a sheet-metal structural part made of a steel alloy or light metal alloy and the reinforcement patch being made of light metal, which is characterized in that the reinforcement patch is an extruded structural part with at least two wall thicknesses differing from one another in cross section.