Nested Fiber-Reinforced Resin Reinforcing Member for Vehicle Frame Bending Resistance

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Solution Overview

Problem

Existing vehicle frame structures are inadequate in suppressing bending deformation caused by load input, which affects the rigidity and stability of the vehicle frame.

Innovation Solution

A vehicle frame structure featuring a closed cross-sectional frame member with a reinforcing member made of fiber-reinforced resin, where the reinforcing member is integrated within the frame to form closed cross-sectional shapes, enhancing the frame's rigidity and dispersing stress through curved surfaces and reinforcing ribs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a conventional closed cross-sectional frame member is used, then the structure is simple, but bending deformation occurs under load

Engineering Contradiction:

Improvebending resistanceVSAvoidframe structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The reinforcing member is disposed inside the frame member, with the reinforcing member's closed cross-section nested within the frame member's closed cross-section. The reinforcing member contacts the inner peripheral surface of the frame member, creating a nested configuration that suppresses bending deformation without significantly increasing external complexity

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The reinforcing member is made of fiber-reinforced resin, which is a composite material combining fibers and resin matrix. This composite structure provides enhanced strength and stiffness to suppress bending deformation while maintaining a relatively lightweight construction

Inventive Principle:

Principle #40Composite materials

2Strength

If the reinforcing member has flat wall surfaces, then manufacturing is easier, but stress concentration occurs

Engineering Contradiction:

Improvestress distributionVSAvoidcurved surface formation

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The wall surfaces of the reinforcing member are formed with curved surfaces instead of flat surfaces. These curved surfaces recess toward the inner side of the frame member, allowing stress to be dispersed more effectively under load, preventing stress concentration at flat surface transitions

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Strength

If the frame member uses only metal materials, then strength is high, but weight increases

Engineering Contradiction:

Improveyield strengthVSAvoidframe weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The reinforcing member is constructed from fiber-reinforced resin, a composite material that combines the strength benefits of fibers with the lightweight properties of resin. This composite structure achieves high yield strength and bending resistance while maintaining lower weight compared to traditional metal-only constructions

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9868465B2Vehicle frame structure

Publication Date: 2018.01.16 TOYOTA JIDOSHA KK

AI summary

A frame structure of a vehicle has: a frame member that is formed in a closed cross-sectional shape having plural first wall portions and plural first corner portions, and that configures a frame of a vehicle; and a reinforcing member that is made of a fiber reinforced resin, and that is formed in a closed cross-sectional shape having plural second wall portions and plural second corner portions, and that is disposed within the closed cross-sectional shape of the frame member such that the plural second corner portions contact the plural first wall portions or the plural first corner portions respectively, the plural second wall portions facing the plural first wall portions or the plural first corner portions respectively, forming plural closed cross-sectional shapes.