Motor Vehicle Support With Force-Fit Reinforcing Element
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Solution Overview
Problem
Existing motor vehicle body-in-white supports, such as side sills, require complex and costly connections to secure reinforcing elements, which can lead to heat-induced misalignment and instability during impacts.
Innovation Solution
A support system with a force-fit engagement between the reinforcing element and the support walls, eliminating the need for additional connections by using a force-fit connection that can be achieved through thermal expansion, pressing, or conical tapering, allowing for reliable and cost-effective integration of the reinforcing element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesively bonded connection or welded connection is used to connect reinforcing element to support walls, then the reinforcing element is secured in position, but the device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and eliminates the separate joining connection (adhesive or weld) from the overall structure. Instead of adding a separate connection mechanism, the support wall itself is designed with an integrated fastening structure that directly engages the reinforcing element, thereby simplifying the device while maintaining reliability
Solution Approach 2:
The invention merges the support wall and the joining function into a single integrated structure. The support wall incorporates direct fastening features (such as protrusions, recesses, or interlocking geometries) that combine structural support and connection functions, eliminating the need for separate joining operations
2Reliability
If welded connection is used to fasten reinforcing element, then secure positioning is achieved, but heat input causes misalignment and structural changes
Solution Approach 1:
The invention replaces the thermal welding process with a mechanical fastening system. The support wall incorporates mechanical interlocking features (such as tabs, slots, or snap-fit structures) that secure the reinforcing element through mechanical engagement rather than thermal fusion, thereby avoiding heat-induced distortion and misalignment
Solution Approach 2:
The support wall structure is designed to self-align and self-secure the reinforcing element through its geometric features. The integrated fastening mechanism automatically positions and locks the reinforcing element in place during assembly, eliminating the need for external alignment procedures or heat treatment processes
3Reliability
If additional joining connections are added to secure reinforcing element, then positioning reliability improves, but production cost and time increase
Solution Approach 1:
The invention combines the support wall and fastening function into a single integrated component. The support wall incorporates built-in fastening features that secure the reinforcing element as part of the primary structure, eliminating the need for separate joining operations and reducing production steps
Solution Approach 2:
The support wall is pre-designed with integrated fastening features during the molding or fabrication process. These pre-formed geometric features (such as protrusions, recesses, or interlocking shapes) are prepared in advance to automatically engage and secure the reinforcing element during assembly, eliminating the need for subsequent joining operations
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 provides a simple, cost-effective, and reliable method for securing reinforcing elements within the support, enhancing stability and preventing misalignment, while avoiding heat input and ensuring secure positioning during the vehicle's lifetime.
Implementation Method 1
The force-fit engagement between the reinforcing element and the respective support walls of the cavity can easily be achieved by suitably heating or cooling the structural parts involved
Implementation Method 2
The force-fit engagement between the reinforcing element and the respective support walls of the cavity can easily be achieved by pressing the reinforcing element into the cavity
Implementation Method 3
the cavities, or the corresponding support walls which delimit the cavities, widen and/or deform slightly elastically or elasto-plastically on account of a slight overdimension of the reinforcing element
Data Source
AI summary
A support for a motor vehicle body-in-white includes a straight longitudinal portion that includes at least one cavity which is delimited by walls of the support and inside of which a reinforcing element is accommodated and is fastened in the longitudinal direction of the support. The reinforcing element is force-locked to the support so as to be fastened in the longitudinal direction of the support.