Side Impact Beam with Plastic Insertion for Crash Stability

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Solution Overview

Problem

Existing side impact beams for motor vehicles, particularly those made of high-strength steel, face premature instability and failure during crashes due to low deformation paths, which is exacerbated by their thin-walled design and limited panel thickness, leading to potential cracking and breaking, especially under stringent crash standards like FMVSS 214.

Innovation Solution

Incorporating a plastic insertion part, preferably made of non-reinforced polyamide or PET, into the steel beam part, which can fill or partially fill the beam's section, providing a relative movement during bending stress and enhancing the beam's strength without a shear-resistant connection, thus preventing premature failure and optimizing weight and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If high-strength steel with thin-walled design is used to reduce weight, then weight is reduced, but premature instability and failure occur during crashes

Engineering Contradiction:

Improvebeam weightVSAvoidcrash performance

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent combines steel beam part with a plastic insertion part to create a composite structure. The steel provides high strength and rigidity for weight reduction, while the plastic insertion part prevents premature instability and failure during crashes through its deformation characteristics, achieving both weight reduction and improved crash performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The plastic insertion part is placed specifically in the central region of the beam where it experiences highest stress during side impacts. This localized reinforcement addresses the critical failure point without requiring the entire beam to be thicker or heavier, maintaining weight efficiency while improving reliability at the most vulnerable location.

Inventive Principle:

Principle #3Local quality

2Strength

If plastic foam filler is introduced to increase strength, then strength is slightly increased, but substantial process costs are incurred

Engineering Contradiction:

Improvebeam strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from plastic foam to solid plastic (polyamide or PET) with specific mechanical properties. This material substitution provides superior strength enhancement without the substantial process costs associated with foam filling, as the solid plastic insertion part can be manufactured and inserted using more cost-effective processes.

Inventive Principle:

Principle #35Parameter changes

3Strength

If insertion part is rigidly connected to beam part to maximize strength, then strength is maximized, but relative movement is prevented during bending stress

Engineering Contradiction:

Improvebeam strengthVSAvoidstructural flexibility

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The connection between the plastic insertion part and steel beam part is designed to be dynamic rather than rigid. The connection allows relative movement during bending stress, enabling the structure to adapt to crash forces through controlled deformation. This dynamic connection maintains strength while preventing premature failure by allowing stress distribution.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS7497504B2Side-on collision beam for a motor vehicle

Publication Date: 2009.03.03 DURA AUTOMOTIVE HLDG U K LTD

AI summary

A side impact beam for a motor vehicle comprising a beam part having a closed section and an insertion part provided in the beam part.