Resin Coupling Structure for Controlled Collision Decoupling
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Solution Overview
Problem
Existing coupling structures in vehicles, such as those between the intake manifold and intercooler, are prone to damage during collisions due to external forces, which can lead to breakage and compromise the protection of other components.
Innovation Solution
A coupling structure featuring welding members and welded members formed of resin, where the welding area on the rear side is smaller than on the front side, allowing for controlled decoupling and stress concentration to prevent damage to the intake manifold during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the welding area on the rear side is made equal to or larger than the front side, then the welding strength is improved, but the stress concentration during collision is reduced, compromising the controlled decoupling capability
Solution Approach 1:
The patent applies asymmetry by making the welding area on the rear side smaller than on the front side. This asymmetric design creates a predetermined weak point that concentrates stress during collision, enabling controlled decoupling while maintaining sufficient welding strength under normal conditions. The asymmetric welding areas allow the coupling to withstand normal forces while failing safely under extreme collision forces.
2Reliability
If the coupling structure is made more robust to prevent damage, then the reliability is improved, but the controlled decoupling capability during collision is compromised
Solution Approach 1:
The patent applies segmentation by dividing the welding structure into regions with different welding areas (front side with larger area, rear side with smaller area). This segmentation creates distinct functional zones: the larger front welding area provides robust connection for normal operation, while the smaller rear welding area serves as a controlled failure point during collision, enabling the coupling to both protect components and decouple when necessary.
3Manufacturing precision
If the welding areas are made symmetric, then the manufacturing precision is simplified, but the stress distribution during collision becomes uniform, preventing controlled decoupling
Solution Approach 1:
The patent deliberately introduces asymmetry in the welding areas to achieve controlled stress distribution during collision. The rear welding area is designed to be smaller than the front welding area, creating a predetermined stress concentration zone. This asymmetric design ensures that during collision, stress concentrates on the smaller rear welding area first, enabling controlled decoupling while the larger front welding area maintains structural integrity.
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 structure effectively reduces the likelihood of damage to the intake manifold by concentrating stress on specific areas, enabling controlled decoupling and maintaining welding strength, thus protecting the component from external forces during vehicle collisions.
Implementation Method 1
a welding member 210 and a welded member 260 that are formed of resin and to which the welding member 210 is welded
Data Source
AI summary
A coupling structure includes a welding member formed of resin and a welded member that is formed of resin and to which the welding member is welded. In the welding member, a region that is welded to the welded member on the rear side in a predetermined direction is smaller than a region that is welded to the welded member on the front side in the predetermined direction.