Pultruded Box Beam Structural Panel for Vehicle Weight Reduction
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Solution Overview
Problem
Existing vehicle panel constructions, such as those using metal frames and sandwich panels, are heavy, prone to deformation in accidents, and do not provide sufficient structural support, leading to increased Gross Vehicle Weight and fuel inefficiency, as well as potential passenger injury.
Innovation Solution
A structural panel assembly featuring pultruded fiberglass reinforcements and thermosetting resin systems, configured as integrated box beams between outer sheets, providing structural support without welding, and optionally incorporating a core material to enhance strength and weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal frames and sandwich panels are used for vehicle construction, then structural support is provided, but the vehicle becomes heavy, increasing Gross Vehicle Weight and reducing fuel efficiency
Solution Approach 1:
The patent employs composite materials throughout its construction: the box beams are made from fiberglass reinforcements embedded in a polyester or vinyl ester resin matrix, the outer sheets are fiberglass-reinforced plastic, and the core material is foam or honeycomb structure. This composite material system provides high strength-to-weight ratio, delivering structural support while minimizing Gross Vehicle Weight compared to traditional metal constructions
Solution Approach 2:
The patent divides the panel into modular segments: separate box beams positioned at selected locations, distinct outer sheets, and a core material filling the space between. This segmentation allows each component to be optimized independently for its specific function while collectively providing the required structural support with reduced overall weight
2Weight of moving object
If known sandwich panel construction is used, then weight is reduced, but sufficient structural support and impact resistance are not provided
Solution Approach 1:
The patent transitions from traditional 2D sandwich panel construction to a 3D structurally enhanced design by incorporating box beams that extend through the thickness of the panel. These box beams create a three-dimensional framework within the panel, adding structural rigidity and impact resistance in multiple directions while maintaining the lightweight sandwich construction principle
Solution Approach 2:
The box beams are designed with curved or rounded corners rather than sharp 90-degree angles. This curvature distributes stress more effectively throughout the beam structure, enhancing impact resistance and structural support while maintaining the lightweight composite construction
3Strength
If welded metal frames are used, then structural integrity is provided, but manufacturing complexity and weight increase
Solution Approach 1:
The patent replaces the mechanical welding process with chemical bonding through resin systems. The box beams are positioned and secured using adhesive bonding between the outer sheets and core material, eliminating the need for welding operations. This substitution simplifies manufacturing by removing complex welding procedures while maintaining structural integrity through the bonded composite construction
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 solution results in a lightweight, impact-resistant panel that minimizes Gross Vehicle Weight, improves fuel economy, and enhances structural integrity, reducing the risk of deformation and injury while maintaining the structural strength needed for vehicle components.
Implementation Method 1
pulling fiberglass reinforcements through a bath of thermosetting resin and into a heated forming-and-curing die to produce composite structural shapes
Implementation Method 2
heated forming-and-curing die
Implementation Method 3
spreading impact forces
Implementation Method 4
bearing weight
Implementation Method 5
bonded to the core materials and the reinforcing member using a bonding material (such as an adhesive)
Data Source
AI summary
A panel construction including one or more pultruded box beams disposed between first and second outer sheets at selected locations. A core or filler material may also be disposed between the first and second outer sheets at selected locations. For example, the core material may be disposed between the first and second outer sheets and fill in the space between the box beams. In another example, the core material may include channels or recesses and the box beams may be positioned in the channels or recesses in the core material.