Hybrid Frame With Concave Deformation For Lightweight Reinforcement
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Solution Overview
Problem
Reinforcing structures for high load-bearing applications, such as automobile components, face challenges in achieving a balance between stiffness, impact resistance, affordability, ease of manufacture, and lightweight design, with existing structures often being heavy and expensive, and having unreliable attachment mechanisms.
Innovation Solution
A hybrid structure comprising a frame member with a channel formed by at least three walls, featuring a convex portion with a concave deformation and a plastic reinforcement member that extends into the channel, allowing for secure and lightweight reinforcement with improved attachment mechanisms through over-molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal reinforcing structures are used to achieve desired stiffness and impact resistance, then structural strength is improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent uses a hybrid structure combining metal frame members with plastic reinforcement members. The plastic components replace portions of metal while maintaining structural integrity, achieving weight reduction of at least 30% compared to all-metal structures while preserving stiffness and impact resistance through the composite action of different materials.
2Strength
If metal inserts are added to achieve desired stiffness, then structural strength is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent integrates the reinforcement function directly into the frame member structure itself. The plastic reinforcement members are incorporated as integral parts of the frame, eliminating the need for separate metal inserts or additional attachment mechanisms. This merging of functions reduces structural complexity while maintaining the required stiffness.
3Reliability
If traditional attachment mechanisms (welding, glue, mechanical fastening) are used to secure reinforcing structures, then attachment strength is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent combines the frame member and reinforcement member into a single integrated component through overmolding. This eliminates the need for separate attachment mechanisms such as welding, adhesives, or mechanical fasteners. The integrated structure is manufactured as one piece, simplifying both manufacturing and assembly processes while ensuring reliable attachment.
4Shape
If complex geometric shapes are formed in metal components, then design flexibility is improved, but manufacturing difficulty and cost increase
Solution Approach 1:
The patent utilizes the different manufacturing characteristics of plastic versus metal. The plastic reinforcement members can be overmolded onto the metal frame to form complex geometric shapes that would be difficult or expensive to manufacture in metal. This leverages the material property differences to achieve complex geometries with easier and lower-cost manufacturing processes.
Data Source
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AI summary
A hybrid structure, comprising: a frame member comprising at least three walls forming a channel having a convex portion where two walls meet; a concave deformation in at least one of the convex portions, wherein the concave deformation extends into the channel and has open ends forming an opening through the convex portion; and a plastic reinforcement member in the channel, wherein a portion of the reinforcement member extends into the opening and on the deformation.