Sheet Metal Crossbar with Inner Structure for Rollover Protection
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Solution Overview
Problem
Existing rollover protective devices for passenger vehicles have limitations in covering a wide lateral area and optimizing material use and deformation capability, often resulting in an unfavorable material-to-deformation ratio and the presence of sharp edges.
Innovation Solution
A rollover protective device featuring a beam-shaped crossbar made from sheet metal with an inner supporting structure, designed to provide a large contact area and optimal material use, incorporating rib- or foot-like supporting units for stability and energy dissipation, and produced through deep drawing and punching processes to avoid sharp edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional roll bar structures are used, then structural strength is provided, but the lateral coverage area is limited and material use is inefficient
Solution Approach 1:
The crossbar is divided into multiple sheet metal components that are assembled together, allowing for optimized material distribution across the lateral coverage area while reducing overall material consumption compared to traditional solid roll bar structures
Solution Approach 2:
The invention transitions from traditional three-dimensional solid or tubular roll bar structures to a two-dimensional sheet metal construction approach, enabling broader lateral coverage with reduced material volume by utilizing surface area efficiency
2Strength
If more material is used to increase deformation capability, then energy absorption improves, but the material-to-deformation ratio becomes unfavorable
Solution Approach 1:
Different regions of the sheet metal crossbar are designed with varying thicknesses and reinforcement levels, concentrating material where deformation capability is most needed while minimizing material use in areas requiring less structural support, thus optimizing the material-to-deformation ratio
Solution Approach 2:
The crossbar employs composite construction combining sheet metal with internal supporting structures and reinforcement elements, achieving high deformation capability through material composition rather than simply increasing overall material quantity
3Weight of moving object
If sheet metal construction is used to reduce weight, then structural efficiency improves, but sharp edges may be formed requiring additional covering
Solution Approach 1:
The sheet metal crossbar components are designed with curved surfaces and rounded edges throughout, eliminating sharp edges through continuous curvature while maintaining structural integrity and weight efficiency of the sheet metal construction
4Area of stationary object
If the crossbar is designed to cover sufficient width, then protection area increases, but structural stability may be compromised
Solution Approach 1:
The wide crossbar is segmented into multiple smaller sheet metal panels connected through reinforcement elements, allowing each segment to maintain structural stability while collectively providing broad protection area
Solution Approach 2:
Internal supporting structures and reinforcement elements are nested within the sheet metal construction, providing structural stability from the inside while the outer sheet metal layers extend to provide broad lateral coverage
Data Source
AI summary
A rollover protective device (1) for a passenger vehicle has a supporting device (3) extending in the vertical elevation (2) when installed correctly. A crossbar (5) is fastened to the supporting device (3) and extends in a lateral direction (4) when installed correctly. The crossbar (5) is of beam-shaped design and is formed by a sheet metal construction (6) with a deformed front side and/or upper side (7, 8) and an inner supporting structure (9).