Multi-Component Trailer Hitch Support with Foam Reinforcement
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Solution Overview
Problem
Existing trailer hitch and load carrier support arrangements face challenges in achieving a balance between rigidity and flexibility, particularly in withstanding rear-end collisions without excessive material usage or increased production costs.
Innovation Solution
A hybrid support component comprising a base body and a reinforcement body, where the base body provides structural integrity and the reinforcement body, often made of engineered foam or light metal, enhances rigidity and energy absorption, with the option of different materials and production methods like press hardening to optimize strength and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid support arrangement is used to support the trailer coupling, then the rigidity and load-bearing capacity are improved, but the flexibility and energy absorption in case of rear-end collision deteriorate
Solution Approach 1:
The support arrangement is divided into multiple functional segments: a base body providing structural support, a reinforcement body enhancing rigidity, and a foam body providing energy absorption. Each segment performs a specific function, allowing the overall system to simultaneously achieve rigidity and impact protection.
Solution Approach 2:
The invention uses a composite structure combining different materials: metal or plastic for the base body, reinforcing materials for the reinforcement body, and foam material for the foam body. This composite approach allows each material to contribute its optimal properties - strength, rigidity, and energy absorption - to the overall system.
2Strength
If more material is used to increase rigidity and strength, then the load-bearing capacity is improved, but the production costs and material usage increase
Solution Approach 1:
Instead of uniformly increasing material throughout the entire support arrangement, the reinforcement body is strategically positioned in specific areas where additional strength is most needed. The foam body is placed in regions where energy absorption is prioritized, optimizing material distribution according to local functional requirements.
Solution Approach 2:
The support arrangement is segmented into distinct functional zones with different material densities and properties. This allows material to be concentrated where structurally necessary while using lighter, less material-intensive solutions in other areas, reducing overall material consumption while maintaining required performance.
3Reliability
If a multi-component hybrid structure is used to achieve both rigidity and energy absorption, then the performance is improved, but the device complexity increases
Solution Approach 1:
Multiple functional components (base body, reinforcement body, foam body) are merged into a single integrated support arrangement that works as a unified system. The components are designed to fit together and function collectively, achieving multiple performance goals simultaneously without requiring separate independent systems.
Solution Approach 2:
The hybrid composite structure combines materials with different properties in a coordinated manner, where each material component contributes specific performance characteristics. This composite approach achieves superior overall performance compared to single-material solutions while managing complexity through material science rather than mechanical 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
The solution achieves high rigidity, energy absorption, and stability while reducing material usage and production costs, allowing for efficient force distribution and impact resistance in trailer hitch and load carrier applications.
Implementation Method 1
the reinforcement body, often made of engineered foam or light metal, enhances rigidity and energy absorption
Implementation Method 2
with the option of different materials and production methods like press hardening to optimize strength and resilience
Data Source
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Figure 9~11
AI summary
The invention relates to a support arrangement (10; 110; 210; 310) for a trailer coupling (1) or a load carrier (L), comprising a cross member (11; 111; 211; 311) and side carriers (12, 112; 212; 312) connected to the cross member (11; 111; 211; 311) for mounting on a rear of a vehicle body (F), and at least one bracket (15; 215; 315) arranged on the cross member (11; 111; 211; 311) for a trailer coupling (1) or for a coupling part (M) of a load carrier (L). The support arrangement (10; 110; 210; 310) is provided to have at least one load-bearing component (50-350) designed as a multi-component component, comprising a base body (16; 116; 216, 316) and a reinforcement body (17-19) connected to the base body (16; 116; 216, 316), which has a rib structure (30; 230; 330) and/or a foam body made of a technical foam.