Vehicle Subframe Reinforcement Using Expandable Pre-foam
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Solution Overview
Problem
Modern vehicle subframes face a challenge in achieving both lightweight and sufficient stiffness to enhance fuel efficiency and reduce manufacturing costs, as thin metal-sheet parts used to minimize weight compromise structural integrity.
Innovation Solution
The method involves using topology optimization to identify high-stress areas in the subframe, where a reinforcement part with a lightweight Polyamide carrier and expandable pre-foam is inserted and secured, allowing the metal-sheet part to be thinned while maintaining structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of the metal-sheet part of the subframe is reduced to decrease weight, then the weight of the subframe is reduced, but the stiffness of the subframe becomes insufficient
Solution Approach 1:
The patent combines metal-sheet parts with polymer foam materials to create a composite structure. The metal-sheet provides structural framework while the foam material provides reinforcement and stiffness. This composite approach allows the metal-sheet to be thinner while maintaining overall structural rigidity, thus reducing weight without sacrificing stiffness.
Solution Approach 2:
The patent applies foam material reinforcement specifically at high-stress areas identified through topology optimization, rather than uniformly throughout the entire subframe. This localized reinforcement provides necessary stiffness where needed while keeping other areas lightweight, resolving the contradiction between overall weight reduction and local stiffness requirements.
2Strength
If topology optimization is used to identify reinforcement areas and foam material is added, then the stiffness of the subframe is improved, but the device complexity increases
Solution Approach 1:
The patent divides the subframe into distinct metal-sheet components and foam material components. The metal-sheet parts maintain their original structural roles while foam inserts are added as separate reinforcement elements. This segmentation allows for modular manufacturing and assembly, managing complexity by keeping components distinct rather than creating a fully integrated complex structure.
Solution Approach 2:
The patent uses topology optimization in the design phase to pre-identify areas requiring reinforcement before manufacturing. This preliminary analysis allows for optimized placement of foam materials, ensuring stiffness requirements are met while avoiding unnecessary reinforcement. The optimization process determines the minimal necessary intervention, preventing excessive complexity.
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
This approach results in a lighter, stiffer subframe that reduces overall vehicle weight and manufacturing costs while ensuring the subframe can withstand dynamic loads effectively.
Implementation Method 1
supplying heat to the pre-foam such that it expands to secure the reinforcement part within the subframe
Data Source
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AI summary
The present invention relates to a method for reinforcing a vehicle subframe comprising one or more hollow metal-sheet parts, wherein the method comprises: a step of determining at least one area on the hollow metal-sheet part of the subframe with respect to specified conditions; a step of preparing a reinforcement part which is able to be inserted in the hollow metal-sheet part of the subframe at said area, wherein the reinforcement part comprises a lightweight carrier for supporting the metal-sheet part and a pre-foam of a foam material which is able to expand after being heated, wherein the lightweight comprises at lease one hollow chamber and wherein the pre-foam is isolated from said at least one hollow chambers and is distributed at least partly on the periphery of the carrier; and a step of installing the reinforcement part within the metal-sheet part of the subframe at the determined area and supplying heat to the pre-foam such that it expands. The present invention also relates to a vehicle subframe reinforced by said method.