Motor Vehicle Subframe Local Foam Reinforcement
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Solution Overview
Problem
Motor vehicle subframes, particularly rear axle supports, are designed to be heavy enough for the heaviest vehicles in a model series, resulting in unnecessary weight for lighter vehicles, which increases investment costs and component weight.
Innovation Solution
A motor vehicle subframe with a base frame and cavity filled locally with rigid foam near force-introduction points, allowing for dimensioning based on the lightest vehicle in the series, providing stability and improved acoustic properties using polyurethane foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the subframe is dimensioned for the heaviest vehicle in a model series, then sufficient operational stability is ensured for all vehicles, but the component weight becomes unnecessarily high for lighter vehicles
Solution Approach 1:
The patent applies local quality by filling only the cavity spaces adjacent to force-introduction points with rigid foam, rather than filling the entire subframe. This localized reinforcement provides sufficient strength for heavy vehicles only where needed, while keeping the overall subframe weight low for lighter vehicle applications.
Solution Approach 2:
The patent uses composite materials by combining the base frame structure with rigid foam filling in specific cavity regions. This composite approach allows the subframe to achieve enhanced strength properties in critical areas while maintaining lightweight characteristics in non-critical areas, resolving the contradiction between strength and weight.
2Ease of manufacture
If the subframe is designed as a universal component for all vehicle types in a model series, then investment costs are reduced, but the structural weight cannot be optimized for lighter vehicles
Solution Approach 1:
The patent implements universality by designing a single subframe configuration that can serve multiple vehicle types within a model series. The base frame provides the universal structure, while the optional rigid foam filling in cavity regions near force-introduction points can be applied as needed to accommodate different vehicle weights, eliminating the need for multiple dedicated subframe designs.
3Strength
If the cavity is filled with rigid foam for heavy vehicles, then sufficient strength is provided, but the subframe weight increases
Solution Approach 1:
The patent applies local quality by filling only the cavity spaces adjacent to force-introduction points with rigid foam, rather than filling the entire subframe. This localized reinforcement provides sufficient strength for heavy vehicles only where needed, while keeping the overall subframe weight low for lighter vehicle applications.
Solution Approach 2:
The patent applies partial action by providing rigid foam filling only in the specific cavity regions where it is needed for structural reinforcement, rather than excessively filling the entire subframe. This partial approach provides sufficient strength for heavy vehicle applications while avoiding unnecessary weight addition in areas where full reinforcement is not required.
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 subframe is significantly lighter and maintains sufficient strength for heavier vehicles, while also enhancing acoustic properties, making it suitable for a range of vehicle configurations without excessive weight.
Implementation Method 1
the cavity is filled locally with rigid foam in the vicinity of the force-introduction point
Implementation Method 2
Foaming of the cavity with rigid foam has the added benefit of also improving the acoustic properties of the subframe
Data Source
AI summary
The invention relates to a subframe (10) for a motor vehicle, having a base frame which forms a cavity and which is connected to a vehicle body via a plurality of fastening points, wherein the base frame has at least one force-introduction point (20) for receiving and/or supporting further motor vehicle components. The invention is characterized in that the cavity is locally filled with rigid foam (24) in the vicinity of the force-introduction point (20).