Long Structural Member With Thick-Wall Corners for Bending Rigidity
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Solution Overview
Problem
Existing long structural members, such as those used in vehicle bodies, face challenges in simultaneously improving three-point bending characteristics and reducing weight, as previous solutions have not adequately investigated the optimal positions and sizes of reinforcing sheet parts.
Innovation Solution
A long structural member design featuring a top plate part and flange parts that are thin, while the side plate parts and corner parts form thick-wall parts, which are produced from a planar blank material by press forming. This configuration enhances flexural rigidity without significantly increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the overall sheet thickness is increased to improve flexural rigidity and three-point bending characteristics, then the three-point bending characteristics improve, but the weight of the long structural member markedly increases
Solution Approach 1:
The patent applies local quality by forming thick-wall parts at specific locations (side plate parts and corner parts) rather than uniformly increasing the thickness of the entire structural member. This localized thickening provides enhanced flexural rigidity and three-point bending characteristics at critical stress areas while maintaining thinner sections in other areas to control overall weight.
Solution Approach 2:
The structural member is segmented into different thickness zones: thin-wall parts (top plate and flange parts) and thick-wall parts (side plates and corner parts). This segmentation allows optimization of material distribution, concentrating material where it is most needed for bending resistance while reducing material in areas where it adds unnecessary weight.
2Strength
If reinforcing sheet parts are joined to the top plate part and upper corner parts to improve three-point bending characteristics, then the thickness of these parts increases and three-point bending characteristics improve, but the weight increases
Solution Approach 1:
The patent extends the thick-wall parts to include the lower corner parts in addition to the side plate parts and upper corner parts. This comprehensive local thickening at all corner positions provides balanced reinforcement against bending loads while maintaining overall weight control through selective placement rather than uniform thickening.
3Strength
If the thickness of specific parts is increased to improve three-point bending characteristics, then the flexural rigidity increases, but the overall weight increase must be suppressed
Solution Approach 1:
The patent implements local quality by creating distinct thick-wall and thin-wall regions. The thick-wall parts (side plates and corner parts) provide high flexural rigidity where bending stresses are concentrated, while the thin-wall parts (top plate and flange parts) reduce overall weight. This localized differentiation optimizes the strength-to-weight ratio.
Solution Approach 2:
The structural member is divided into functional segments with different thickness characteristics. The segmentation into thick-wall and thin-wall parts allows each region to be optimized for its specific structural role, achieving high flexural rigidity through strategic material placement rather than uniform material distribution.
Data Source
AI summary
A long structural member that, in a transverse section of one part or all of the long structural member in a longitudinal direction, includes the following configuration. A top plate part, a first flange part, and a second flange part are flat. A first side plate part, a first upper corner part, and a first lower corner part constitute a first thick-wall part. A thickness of the first thick-wall part is greater than a thickness of the top plate part and is greater than a thickness of the first flange part. A second side plate part, a second upper corner part, and a second lower corner part constitute a second thick-wall part. A thickness of the second thick-wall part is greater than the thickness of the top plate part and is greater than a thickness of the second flange part.