Loading Bracket for Composite Vehicle Structures
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Solution Overview
Problem
Vehicle structural components made of lightweight materials like composite materials face challenges in attaching high-load accessories such as tow hooks and roof cargo carriers without compromising their structural integrity, as they struggle to distribute loading forces effectively.
Innovation Solution
A loading bracket assembly that redirects loading forces from composite structural components to a supportive structure of the vehicle, minimizing the need for holes or openings in the composite material by using a base bracket with an engagement portion within the composite beam and a fastener to transfer forces to a supportive structure, thereby increasing the component's load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight composite materials are used for vehicle structural components, then vehicle weight is reduced and performance is improved, but the ability to attach high-load accessories and distribute loading forces is compromised
Solution Approach 1:
A metal bracket is introduced as an intermediary component between the composite structural component and the accessory requiring high load support. The bracket receives loading forces from the accessory and transfers them to the composite component, enabling the lightweight composite material to support high-load accessories without compromising its weight advantages.
2Strength
If attachment structures are added to composite components to support high-load accessories, then load-bearing capacity is improved, but the structural integrity of the composite component is compromised due to holes or openings
Solution Approach 1:
The metal bracket serves as a mediator that attaches to the composite component through minimal openings or surface mounting, thereby supporting high-load accessories without requiring large holes or structural modifications that would compromise the composite component's integrity.
Solution Approach 2:
The solution employs a hybrid approach combining metal (bracket) and composite materials (structural component), where each material is used in the form best suited for its mechanical properties - metal for load transfer and composite for lightweight structural support.
Data Source
AI summary
A loading bracket assembly includes a base bracket having an engagement portion that is disposed at an interior area of a composite vehicle structural component and that is accessible through the first wall. A fastener may be attached to the engagement portion of the base bracket and may extend through an intermediate wall of the composite vehicle structural component and a supportive structure of the vehicle. The engagement portion of the base bracket is configured to engage a component or an accessory, such as a tow hook, that applies a loading force to the base bracket that is substantially transferred to the supportive structure and bypasses the composite vehicle structural component.