In-Vehicle Component Support Structure Using Segmented Metal and Resin Braces
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Solution Overview
Problem
Existing support structures for in-vehicle components, such as cowl braces, face issues with increased weight and vibration transmission due to the use of metal materials, which compromise weight reduction and vibration damping.
Innovation Solution
A support structure comprising a first metal brace attached to the vehicle body frame and a second resin brace, where the resin brace is lighter and has a higher vibration damping rate, effectively reducing the overall weight and suppressing vibrations of attached components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal brace is used to support in-vehicle components, then the strength and rigidity are sufficient, but the weight increases and vibration damping performance deteriorates
Solution Approach 1:
The brace is divided into two separate braces: a first metal brace attached to the vehicle body frame and a second resin brace attached to the first brace. This segmentation allows each brace to be optimized for its specific function - the metal brace provides structural strength while the resin brace provides vibration damping and weight reduction.
Solution Approach 2:
The support structure uses composite materials by combining metal and resin in a hierarchical arrangement. The metal brace (aluminum alloy or steel) provides high strength and rigidity, while the resin brace (polypropylene or polycarbonate) provides vibration damping and weight reduction, achieving a balance between strength and weight.
2Strength
If a metal brace is used to support in-vehicle components, then the structural strength is maintained, but the vibration damping rate is insufficient
Solution Approach 1:
The single metal brace is segmented into two braces with different materials. The second resin brace acts as a vibration damping element that absorbs and dissipates vibrations before they reach the in-vehicle components, while the first metal brace maintains the overall structural strength.
Solution Approach 2:
The second resin brace serves as an intermediary element between the first metal brace and the in-vehicle components. It mediates the transmission of vibrations by absorbing and damping them, preventing direct transmission of harmful vibrations to the components.
3Length of moving object
If the brace length is increased to maintain structural integrity, then the support span is sufficient, but the weight increases
Solution Approach 1:
The use of resin material for the second brace provides a favorable strength-to-weight ratio, allowing the brace length to be sufficient for structural integrity while keeping the weight low. Resin materials have lower density than metals, enabling long braces without excessive weight gain.
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 combination of a metal and resin brace structure maintains strength while minimizing weight increase and effectively dampens vibrations, enhancing the stability and efficiency of the support system.
Implementation Method 1
the second brace is formed of a material that is lighter in weight and higher in vibration damping rate than the first brace
Data Source
AI summary
There is provided a support structure for an in-vehicle component that supports an in-vehicle component at a front side of a vehicle body frame. The support structure for an in-vehicle component includes a first brace that is attached to a front portion of the vehicle body frame, and a second brace that is attached to a front portion of the first brace. The in-vehicle component is attached to the second brace, and the second brace is made of a material lighter in weight and higher in vibration damping rate than the first brace.