Plastic Cowl Crossbar with Composite Winding for Weight Reduction
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Solution Overview
Problem
Conventional cowl crossbars, typically made of aluminum, increase vehicle weight, which worsens fuel efficiency, and their design does not adapt well to the shape of slim cockpit structures in autonomous vehicles, requiring a more lightweight and rigid solution.
Innovation Solution
A lightweight cowl crossbar made of plastic material, specifically polypropylene with glass fiber reinforcement, featuring an integrally molded design with a winding layer of single oriented fiber composite material, including a gear structure and shock-absorbing components, to provide both rigidity and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum material is used for cowl crossbar, then strength and rigidity are improved, but vehicle weight increases
Solution Approach 1:
The patent uses composite materials consisting of polypropylene resin and glass fibers to create a cowl crossbar that achieves high strength and rigidity while maintaining lightweight properties. The glass fiber reinforcement provides structural strength comparable to aluminum, while the polypropylene matrix keeps the overall weight low, thus resolving the contradiction between strength and weight.
Solution Approach 2:
The patent optimizes the composition parameters of the composite material, specifically controlling the glass fiber content (30-70 wt%) and using specific polypropylene resin types to achieve the desired balance between strength and weight. By adjusting these material parameters, the cowl crossbar achieves aluminum-level strength with reduced weight.
2Stability of the object's composition
If conventional aluminum cowl crossbar structure is used, then rigidity is maintained, but adaptability to slim cockpit shapes is reduced
Solution Approach 1:
The patent utilizes the molding characteristics of plastic composite materials to create varied cross-sectional shapes and structural configurations that adapt to different cockpit designs. The material's formability allows for optimized structural parameters while maintaining rigidity, enabling adaptation to slim cockpit shapes without compromising structural stability.
Solution Approach 2:
The cowl crossbar is designed with segmented structural features including reinforcement ribs, varying wall thicknesses, and integrated mounting points that can be strategically positioned to maintain rigidity while accommodating different cockpit geometries. This segmentation allows the structure to be optimized for both strength and adaptability.
3Weight of moving object
If plastic material is used for cowl crossbar, then weight is reduced, but perceived strength and rigidity may be insufficient
Solution Approach 1:
The patent employs composite materials with glass fiber reinforcement in a polypropylene matrix to achieve high strength-to-weight ratio. The glass fibers provide tensile strength and stiffness comparable to aluminum, while the plastic matrix binds the fibers and provides structural continuity, resulting in a lightweight yet strong cowl crossbar that dispels the misconception that plastic cannot provide sufficient strength.
Solution Approach 2:
The composite material structure serves multiple functions simultaneously: the glass fibers provide strength and stiffness, the polypropylene matrix provides structural continuity and impact absorption, and the integrated design provides mounting functions. This multi-functionality allows the lightweight structure to meet all structural requirements without compromising strength.
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
The plastic cowl crossbar achieves stable rigidity and weight reduction, improving fuel efficiency while accommodating various vehicle cockpit shapes, including those of autonomous vehicles.
Implementation Method 1
a winding layer which is formed along the outer surface of the inner pipe; and an outer pipe which is located on the upper surface of the winding layer
Data Source
AI summary
A lightweight cowl crossbar includes: a first cowl crossbeam located on a first side frame disposed at a first side of a vehicle body; a second cowl crossbeam fastened to the first cowl crossbeam and fixed to a second side frame disposed at a second side of the vehicle body; a support leg located on the second cowl crossbeam and configured to be supported by the vehicle body, and a drawing block part located on a region where the first cowl crossbeam and the second cowl crossbeam overlap.