Staged Deformation Reinforcement Structure for Vehicle Impact Loads
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Solution Overview
Problem
Existing vehicle structural reinforcements that improve crash impact performance result in increased vehicle weight, compromising fuel efficiency, and there is a need for a system that distributes impact loads in a controlled manner to prevent deformation into the passenger compartment.
Innovation Solution
A structural reinforcement system featuring a carrier with varying height projections and an activatable material that deforms in stages to absorb and distribute impact loads, using a molded polymeric carrier with localized fiber reinforcement and a heat-activatable adhesive that secures the structure within a vehicle cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard heavier metal reinforcements are used to provide effective structural reinforcement, then crash impact resistance is improved, but vehicle weight increases and fuel efficiency decreases
Solution Approach 1:
The reinforcement structure is segmented into multiple projections of varying heights (first projections, second projections, third projections) that deform sequentially during impact. This segmentation allows the structure to absorb energy in stages rather than requiring a single heavy solid structure, achieving crash resistance with reduced weight.
Solution Approach 2:
The patent changes the geometric parameters of the reinforcement structure by creating projections with different heights and configurations. This parameter variation enables progressive deformation during impact, providing effective crash resistance while using less material weight compared to traditional solid metal reinforcements.
2Device complexity
If a single-stage deformation structure is used, then structural simplicity is maintained, but impact load distribution and energy absorption are insufficient
Solution Approach 1:
The deformation process is segmented into multiple stages corresponding to the different projection heights. During impact, first projections (tallest) deform first, followed by second projections, then third projections (shortest). This segmentation multiplies energy absorption capacity without significantly increasing structural complexity.
Solution Approach 2:
The structure transitions from a static configuration to a dynamic progressive collapse sequence during impact. The varying projection heights create a controlled dynamic deformation pattern that maximizes energy absorption while maintaining relatively simple structural geometry.
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 system effectively absorbs and distributes impact loads through staged deformation, reducing the load transferred to the vehicle interior while maintaining structural integrity and weight, thus enhancing vehicle safety and reducing fuel consumption.
Implementation Method 1
the activatable material may be activated by heat in an automotive vehicle painting operation (i.e., paint bake oven)
Implementation Method 2
the deformation of the at least one first projection and/or the at least one second projection in response to the impact load may be plastic deformation
Implementation Method 3
the at least one first projection is configured to receive the impact load and deform before the at least one second projection receives the impact load and deforms
Data Source
AI summary
A structural reinforcement for a vehicle comprising: a) a carrier having a base wall from which a plurality of projections extend, the plurality of projections including at least one first projection and at least one second projection and the at least one first projection having a height greater than a height of the at least one second projection; b) an activatable material which is heat activatable and affixed to the carrier, configured to secure the carrier in a cavity of the vehicle; wherein in event of an impact, the at least one first projection and second projection are configured to deform toward the base wall and/or in a direction of an impact load in response to the impact load; and the at least one first projection is configured to receive the impact load and deform before the at least one second projection receives the impact load and deforms.