Internal Brace for Automotive Frame Structural Stability
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Solution Overview
Problem
Conventional solutions to meet increasing Federal safety requirements for vehicle roof loads result in increased weight and cost, as adding heavy steel reinforcements to maintain structural integrity leads to a 'Catch 22' situation where added structure increases load requirements, and lightweight materials are expensive.
Innovation Solution
A stability device featuring an internal lightweight brace spanning across the cross-sectional configuration of a vehicle structural frame member, formed from thin materials and welded between hat-shaped components, maintains geometric shape under load without significant weight increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy steel reinforcements are added to meet Federal safety requirements, then load carrying capacity is improved, but vehicle weight increases which ultimately increases load requirements
Solution Approach 1:
The patent utilizes thin film-like structures (0.020 to 0.063 inch thick steel sheets) formed into hat-shaped cross-sections that provide high strength-to-weight ratio. These thin-walled structures achieve the required load carrying capacity through optimized geometric shape rather than mass, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The invention creates a composite structure by joining multiple hat-shaped members together with internal braces to form an integrated frame assembly. This composite approach allows the structure to achieve higher load carrying capacity than individual components while maintaining lightweight characteristics, as the synergistic arrangement provides enhanced strength without proportional weight increase.
2Strength
If frame size is increased to meet load requirements, then structural integrity is improved, but load requirements increase due to added weight
Solution Approach 1:
The hat-shaped cross-sections feature curved surfaces and optimized geometric profiles that provide high structural integrity for their weight. The curved geometry distributes stresses more effectively than flat sections, allowing the frame to maintain strength without increasing mass, thus avoiding the catch-22 of increased load requirements.
Solution Approach 2:
The invention transitions from traditional solid bar structures to thin-walled hollow hat-shaped sections, effectively utilizing the third dimension (hollow interior space) to achieve high moment of inertia and bending resistance without adding mass. This dimensional approach allows the frame to resist bending and crushing loads efficiently while maintaining lightweight characteristics.
3Strength
If conventional steel reinforcements are used, then load carrying capacity is improved, but manufacturing cost increases
Solution Approach 1:
The frame structure is segmented into multiple hat-shaped members that can be manufactured independently using standardized forming and welding processes. This segmentation allows for efficient production, quality control, and assembly, reducing manufacturing costs while achieving the required load carrying capacity through the optimized geometry of each segment.
Solution Approach 2:
The invention optimizes the thickness parameter of the steel sheets (0.020 to 0.063 inches) to achieve the best balance between load carrying capacity and material cost. By carefully selecting and varying thickness parameters across different frame members, the design achieves required strength while minimizing material consumption and manufacturing cost.
Data Source
AI summary
A vehicle structural frame member incorporates an internal lightweight brace member spanning between the opposing flanges of the co-joined hat-shaped members forming the structural frame member. The internal brace is formed of thin material, such as steel, to help the frame member retain its geometric shape when placed under a load. The internal brace can be formed into a ladder-like configuration with longitudinally spaced members that span between the opposing flanges to keep the geometric shape from collapsing. A substantial improvement in load carrying capability before collapse is obtained with a small increment in additional weight in the structural frame member.