Laminate Forming for Localized Composite Crash Reinforcement
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Solution Overview
Problem
Current methods for reducing vehicle body weight to improve fuel efficiency and emissions face challenges in maintaining structural integrity and crashworthiness, particularly in high-speed crashes and rollovers, as they often require additional processing steps, heavy materials, or homogeneous reinforcement that does not account for three-dimensional design variations.
Innovation Solution
The use of energy-absorbing devices comprising a hybrid structure of continuous fiber reinforced-polymer composites and chopped fiber reinforced thermoplastics, which can be positioned in hollow channels of vehicle components, providing localized reinforcement with varying geometries to absorb impact energy while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If homogeneous reinforcement is used throughout the vehicle body, then structural integrity is improved, but weight reduction is limited and three-dimensional design variations cannot be accounted for
Solution Approach 1:
The patent applies local quality by transitioning from homogeneous reinforcement to localized energy-absorbing devices positioned specifically in hollow channels of vehicle components. These devices provide reinforcement only where needed for crashworthiness, allowing weight reduction in non-critical areas while maintaining structural integrity through targeted reinforcement with varying geometries and material properties matched to local requirements.
Solution Approach 2:
The patent segments the vehicle body structure into discrete components with hollow channels, into which individual energy-absorbing devices are inserted. This segmentation allows each device to be independently optimized for its specific location and function, rather than requiring uniform reinforcement throughout the entire vehicle body, thereby enabling both weight reduction and tailored structural performance.
2Reliability
If additional processing steps are added to maintain structural integrity during weight reduction, then crashworthiness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the energy-absorbing device insertion with the existing vehicle component manufacturing process. The energy-absorbing devices are designed to be inserted into hollow channels that are already part of the vehicle component design, combining the structural reinforcement function with the existing manufacturing workflow without requiring additional separate processing steps or complex assembly operations.
3Strength
If heavier materials are used to maintain structural integrity, then crash resistance is improved, but weight reduction goals are compromised
Solution Approach 1:
The patent employs composite materials in the energy-absorbing devices, combining different materials with complementary properties to achieve high crash resistance at reduced weight. The devices utilize varying geometries and material compositions tailored to specific locations, providing superior strength-to-weight ratio compared to traditional homogeneous heavy materials, while maintaining the required crashworthiness through optimized material distribution.
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 solution allows for a significant reduction in vehicle weight without compromising safety, offering improved crash resistance and structural integrity comparable to all-metal systems, while being lighter and more efficient in energy absorption, and can be manufactured without additional processing steps.
Implementation Method 1
increasing a temperature and a pressure to flow the resin into the fiber structure to form the laminate
Implementation Method 2
cooling the laminate to solidify and form the shell
Implementation Method 3
providing localized reinforcement with varying geometries to absorb impact energy while maintaining structural integrity
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
a method of forming a laminate (114) comprising feeding a fiber structure (104) and a resin film (102) to a heated belt (100) to form layup; increasing a temperature and the pressure to flow the resin into the fiber structure to form the laminate and cooling the laminate to solidify the laminate.