Hybrid Quarter Module for Front Underrun Protection

Solution Overview

Problem

Current front underrun protection devices for vehicles, typically made of steel, are heavy, labor-intensive, and complex to manufacture and assemble, while pure polymeric solutions fail to meet safety standards such as ECE-R93.

Innovation Solution

A lightweight, hybrid front underrun protection system combining a metal housing member with polymeric inserts, designed to be easily assembled and manufactured, featuring a housing member with a base plate, arm, and polymeric inserts that provide structural integrity and energy absorption, meeting or exceeding safety standards with significant weight reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If steel is used for front underrun protection devices, then strength and safety performance are improved, but weight and manufacturing complexity increase

Engineering Contradiction:

ImprovestrengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining polymeric material with metal reinforcement elements (such as steel beams or aluminum profiles) to create a hybrid structure. The polymeric material provides energy absorption and lightweight properties, while the metal reinforcement ensures structural strength and stiffness. This composite approach allows the device to meet safety requirements while reducing overall weight compared to pure steel constructions.

Inventive Principle:

Principle #40Composite materials

2Strength

If steel is used for front underrun protection devices, then strength and safety performance are improved, but manufacturing complexity and assembly difficulty increase

Engineering Contradiction:

ImprovestrengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the underrun protection device into modular components: polymeric sections and metal reinforcement elements. These segments can be manufactured separately using different processes (injection molding for polymer, fabrication for metal) and then assembled together. This modular approach simplifies manufacturing by allowing specialized production methods for each material type and facilitates easier assembly and potential replacement of individual components.

Inventive Principle:

Principle #1Segmentation

3Weight of moving object

If pure polymeric material is used, then weight is reduced, but strength and safety standard compliance deteriorate

Engineering Contradiction:

ImproveweightVSAvoidstrength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies composite materials by combining polymeric material with metal reinforcement elements (such as steel beams or aluminum profiles) to create a hybrid structure. The polymeric material provides energy absorption and lightweight properties, while the metal reinforcement ensures structural strength and stiffness. This composite approach allows the device to meet safety requirements while reducing overall weight compared to pure steel constructions.

Inventive Principle:

Principle #40Composite materials

4Weight of moving object

If pure polymeric material is used, then weight is reduced, but energy absorption capability under high load deteriorates

Engineering Contradiction:

ImproveweightVSAvoidenergy absorption

Core Design Contradiction:

Weight of moving objectVSLoss of energy

Solution Approach 1:

The patent applies composite materials by combining polymeric material with metal reinforcement elements (such as steel beams or aluminum profiles) to create a hybrid structure. The polymeric material provides energy absorption and lightweight properties, while the metal reinforcement ensures structural strength and stiffness. This composite approach allows the device to meet safety requirements while reducing overall weight compared to pure steel constructions.

Inventive Principle:

Principle #40Composite materials

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 hybrid system achieves weight reductions of over 20% compared to steel solutions while meeting or exceeding safety standards, simplifying manufacturing and assembly, and providing effective energy absorption during collisions.

Implementation Method 1

a front collision absorbing member provided along the vehicle width direction on the front surface of the beam member

Methodology Applied

Scientific EffectEnergy absorption: Deformation

Data Source

PatentEP2956337B1Hybrid quarter module design for front underrun protection device

Publication Date: 2017.03.22 SABIC GLOBAL TECHNOLOGIES BV

AI summary

In an embodiment, a component for an underrun protection device can comprise: a housing member (10), comprising a main body (100) having a base plate (108) with a top wall (103), bottom wall (109), and optional side walls (104), extending from one side of the base plate (108) to form a housing (115); an arm (101) extending from another side of the base plate (108), wherein the arm (101) comprises a base (109) in contact with the base plate (108), arm sides (105) that extend from the base (109) toward a connection area (107), wherein the arm sides (105) form an arm channel (113); a body polymeric insert (200) comprising body insert ribs (202) and body insert channels (204); and an arm polymeric insert (300) comprising arm insert ribs (302) and arm insert channels (304), wherein the arm polymeric insert (300) is located in the arm channel (113).