Cold-Bent Reinforcement Member Tab Without Coating Cracks
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Solution Overview
Problem
Reinforcement members made of high-strength press hardened steel coated with zinc or aluminum, used to prevent vehicle deformation in impacts, face issues with tab attachment due to potential fracture and coating damage during bending, leading to reduced mechanical properties and corrosion resistance.
Innovation Solution
A reinforcement member with a tab made from a cold-bent part of the body, where the elongation of the extrados is between 10% and 25%, allowing for significant angle bending without fracturing the member or damaging the coating, even with thick reinforcement members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tab is bent from the reinforcement member to attach to a surrounding part, then the attachment reliability is improved, but the coating quality deteriorates due to cracks and the reinforcement member may fracture
Solution Approach 1:
The patent changes the bending parameters by controlling the bend radius to be at least 5 times the thickness of the reinforcement member and limiting the bending angle to a specific range. This parameter optimization allows the tab to be formed without causing coating cracks or member fracture, resolving the contradiction between attachment reliability and coating quality
Solution Approach 2:
The tab is formed by bending during the manufacturing process before the reinforcement member is installed and before any impact occurs. This preliminary formation of the tab with controlled parameters prevents coating damage that would occur during later attachment operations, while ensuring the tab is ready for reliable attachment
2Strength
If the reinforcement member has increased thickness to improve impact resistance, then the strength is improved, but the bending operation becomes more difficult and increases the risk of fracture
Solution Approach 1:
The patent establishes a specific relationship between bend radius and member thickness (R ≥ 5t) that scales with thickness. This allows thicker members to be bent without increasing fracture risk, as the larger bend radius accommodates the increased thickness while maintaining manufacturing feasibility and structural integrity
3Adaptability or versatility
If a large bending angle is used to attach the tab to surrounding parts in different directions, then the adaptability is improved, but the risk of fracture and coating damage increases
Solution Approach 1:
The patent defines an optimal bending angle range that balances adaptability and reliability. By limiting the bending angle to specific ranges and combining this with adequate bend radius (R ≥ 5t), the tab can achieve sufficient angular deflection for various attachment directions while preventing the excessive stress that would cause fracture or coating damage
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 method enables reliable attachment of the reinforcement member to surrounding parts without fracturing or degrading the coating, maintaining mechanical properties and corrosion resistance, thus effectively preventing deformation in vehicle impacts.
Implementation Method 1
said tab being made of a cold bent part of the body
Implementation Method 2
the elongation of the extrados being comprised between 10% and 25%
Data Source
AI summary
The reinforcement member includes a body made of a press hardened steel having a tensile strength greater or equal to 1200 MPa. The body is coated with a zinc-based coating or with an aluminum-based coating and extends along a main direction. The reinforcement member also includes at least one tab extending from the body along a transversal direction forming a non-zero angle with the main direction. The bend between the body and the tab defines an intrados and an extrados. The tab is made of a cold bent part of the body, and the elongation of the extrados is between 10% and 25%.