Hybrid Vehicle Structural Component with Foam-Filled Chambers
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Solution Overview
Problem
Current structural components for motor vehicles face challenges in achieving high energy absorption potential while maintaining stability and low weight, with existing production methods being costly and time-consuming.
Innovation Solution
A method involving a hybrid component with a tubular FRP or metal carrier part reinforced by an injection-molded ribbed plastic stiffening structure, where additional plastic foam is integrated into the chambers formed by the stiffening structure to enhance energy absorption and rigidity, using a two-component injection molding process with a rotatable tool containing separate nozzles for each plastic application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If structural components use heavier materials or thicker walls to increase energy absorption capacity, then energy absorption capacity is improved, but weight increases
Solution Approach 1:
The patent employs a hybrid construction combining a metal or FRP support element with injection-molded plastic stiffening structures and foam material. This composite approach allows the component to achieve high energy absorption capacity through the combination of rigid support elements and energy-absorbing foam, while maintaining low weight by using lightweight plastics and avoiding solid metal filling throughout the entire structure.
Solution Approach 2:
The foam material is selectively introduced only into specific chambers formed by the ribbed stiffening structure, rather than filling the entire component. This local application of foam allows energy absorption to be concentrated in areas where it is most needed during impact, while other areas maintain structural integrity without the added weight of foam filling.
2Manufacturing precision
If multiple separate manufacturing processes are used to create the stiffening structure and fill chambers, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent integrates the formation of the stiffening structure and the filling of chambers into a single continuous injection molding process. The injection mold includes multiple cavities that simultaneously form the ribbed stiffening structure and fill the chambers with foam material in one operation, eliminating the need for separate manufacturing steps while maintaining precise geometric relationships between components.
Solution Approach 2:
The injection mold serves multiple functions simultaneously: it forms the plastic stiffening structure, creates the ribbed geometry, and fills the chambers with foam material all in one process cycle. This multi-functional tooling approach maintains manufacturing precision while dramatically increasing production efficiency compared to sequential processes.
3Ease of manufacture
If a single-component structure is used to simplify manufacturing, then ease of manufacture is improved, but energy absorption capacity decreases
Solution Approach 1:
The component is divided into distinct functional zones: a rigid support element (metal or FRP), plastic stiffening ribs that provide structural integrity, and foam-filled chambers that provide energy absorption. This segmentation allows each material to perform its optimal function while the entire assembly is manufactured as an integrated hybrid component in a single process.
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 results in structural components with increased energy absorption capacity and stability, reduced weight, and cost-effective, quick production, enabling improved performance in impact scenarios and pedestrian protection.
Implementation Method 1
a further plastic, in particular a foam, is arranged in the at least one chamber... which differs from the stiffening structure, the energy absorption capacity and/or the stiffness is thus increased
Implementation Method 2
injection-molded, ribbed stiffening structure made of plastic... a two-component injection molding process
Data Source
Figure 1
Figure 2a~2d
Figure 2e~2f
AI summary
The invention relates to a structural component (18) for a motor vehicle, comprising at least one support part (24), in particular a fiber-reinforced plastic or metal support part, which is reinforced at least in some sections by a reinforcing structure (32) made of plastic to form a hybrid component, wherein at least one chamber (42) of the hybrid component is at least partially bounded by the reinforcing structure (32), wherein a further plastic (44), in particular a foam, is arranged in the at least one chamber (42). The invention further relates to a structural component, the reinforcing structure of which is made of a foam or plastic foam (62, 64), and to production methods in which the various required steps, such as deep-drawing, extruding, shaping using internal high pressure, expanding, etc., are carried out in a single apparatus.