Resin-Coated Automotive Frame Part for Fracture-Resistant Bending
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Solution Overview
Problem
Existing automotive frame parts, such as pillars and side sills, fail to effectively absorb crashworthiness energy by bending due to fracturing during collisions, despite efforts to improve strength and impact energy absorption through foamed resin filling.
Innovation Solution
An automotive frame part with a hat-shaped or U-shaped cross section, coated with resin on its internal surface, featuring punch shoulder R portions that prevent resin release during bending, ensuring an adhesive strength of 10 MPa or higher at room temperature, and a release prevention member to maintain resin adherence and prevent fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foamed resin is filled inside the automotive frame part, then the strength and impact energy absorptiveness are improved, but the member fractures during bending caused by collision
Solution Approach 1:
The resin is selectively coated on specific internal surfaces (flange inner surface, side wall inner surfaces, and bottom inner surface) rather than uniformly filling the entire space. This localized coating approach provides targeted reinforcement at critical stress points while maintaining the member's ability to bend without fracture, resolving the contradiction between strength improvement and fracture resistance.
Solution Approach 2:
The invention combines the metal frame member with a resin coating to create a composite structure. The resin-coated frame member integrates two materials with complementary properties: the metal provides structural framework and bendability, while the resin enhances impact energy absorptiveness and prevents fracture during collision-induced bending.
2Use of energy by moving object
If the frame part is designed to absorb crashworthiness energy by bending, then the energy absorption capability is improved, but the deformation resistance deteriorates due to fracturing
Solution Approach 1:
The resin is coated on the internal surfaces of the frame member before the collision occurs. This pre-applied resin layer acts as a cushioning layer that prevents fracture during the bending process, allowing the member to maintain its deformation resistance throughout the energy absorption process without catastrophic failure.
Solution Approach 2:
The composite structure of metal frame with resin coating provides both the necessary deformation resistance and energy absorption capability. The resin-reinforced regions maintain structural integrity during bending, enabling sustained deformation resistance while absorbing crashworthiness energy.
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 enhances crashworthiness energy absorption by preventing fractures and improving buckling strength, thereby increasing the frame's ability to absorb energy without deformation resistance deterioration.
Implementation Method 1
the coated or patched resin is adhered, after heating, to the internal surface and the release prevention member at an adhesive strength of 10 MPa or higher at a room temperature
Implementation Method 2
the coated or patched resin extends at least to a predetermined range toward the top portion and the side wall portions on both sides of the punch shoulder R portions, and the coated or patched resin is adhered, after heating, to the internal surface and the release prevention member
Data Source
Figure 1~2
Figure 3(a)~4
Figure 5~6
AI summary
An automotive frame part 1 according to the present invention is an automotive frame part that is provided to a side portion of an automotive body, and that absorbs crashworthiness energy by bending upon receiving a crashworthiness load from the side of the automotive body, and includes an outer part 3 that has a top portion 3a, and a pair of side wall portions 3c that are continuous from the top portion 3a via punch shoulder R portions 3b, and resin 7 that is coated on the internal surface of the outer part 3. The coated resin 7 extends at least to a predetermined range toward the top portion 3a and the side wall portions 3c on both sides of the punch shoulder R portions 3b, the resin 7 being caused to adhere, after heating, to the internal surface at an adhesive strength of 10 MPa or higher at a room temperature.