UHMWPE Composite Bracket for Vehicle Running Board
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Solution Overview
Problem
Vehicles with high ground clearance, such as SUVs and trucks, present difficulties for users when entering and exiting due to elevated floor levels, and existing running board brackets may not provide sufficient support or durability.
Innovation Solution
A bracket made from ultra-high-molecular-weight-polyethylene (UHMWPE) combined with a stiffening filler, such as glass, basalt, or carbon fibers, is formed using extrusion or compression molding, providing high impact resistance and stiffness, and is designed with an L-shape and ribs for secure attachment to the running board and vehicle body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal brackets are used to connect running boards to vehicle bodies, then structural strength is achieved, but weight increases and corrosion resistance decreases
Solution Approach 1:
The patent applies composite materials by combining UHMWPE base material with stiffening fillers (glass fibers, basalt fibers, or carbon fibers) to create a bracket that achieves metal-level structural strength while maintaining the weight and corrosion resistance advantages of polymer materials. The composite structure allows the bracket to meet structural requirements without the drawbacks of traditional metal brackets.
2Weight of moving object
If traditional polymer materials are used for brackets, then weight reduction is achieved, but stiffness and impact resistance are insufficient
Solution Approach 1:
The patent uses composite materials comprising UHMWPE combined with stiffening fillers (glass fibers, basalt fibers, or carbon fibers) to achieve both weight reduction and enhanced stiffness. The fiber reinforcement provides the necessary structural rigidity and impact resistance while the UHMWPE matrix maintains low weight and corrosion resistance.
Solution Approach 2:
The patent changes the material parameters by selecting specific fiber types and lengths (12-25 mm) and optimizing the composition ratios (30-70% UHMWPE, 70-30% stiffening filler) to achieve the desired balance between stiffness, impact resistance, and weight. The LLDPE/CB/MAH copolymer addition further modifies material parameters to enhance interfacial bonding and overall performance.
3Reliability
If metal brackets are used, then durability is improved, but temperature resistance and corrosion resistance worsen
Solution Approach 1:
The patent replaces traditional metal brackets with a polymer-based composite bracket that, while potentially having different service life characteristics, provides superior temperature resistance and corrosion resistance. The UHMWPE composite material is specifically selected for its ability to maintain performance across extreme temperature ranges and resist environmental degradation that affects metal brackets.
4Strength
If UHMWPE is used for the bracket, then impact resistance and temperature resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes manufacturing parameters by specifying precise processing conditions: heating to 280-300°F (138-149°C) for extrusion, maintaining fiber lengths of 12-25 mm, and controlling material composition ratios. These parameter specifications enable consistent production of UHMWPE composite brackets with desired performance characteristics while managing manufacturing complexity through standardized processes.
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 resulting bracket offers enhanced durability, temperature resistance, and reduced weight, allowing for easier vehicle access while maintaining structural integrity and performance in low temperatures.
Implementation Method 1
heating the mixture, within the extruder, as the hydraulic ram applies pressure to the mixture to extrude the component
Implementation Method 2
the extruded component is heated to between about 280° F. and 300° F. (between about 138° C. and about 149° C.), shaped, and allowed to cool
Implementation Method 3
the extruded component is heated to between about 280° F. and 300° F. (between about 138° C. and about 149° C.), shaped, and allowed to cool
Data Source
AI summary
A method of forming a component for a vehicle according to an exemplary aspect of the present disclosure includes, among other things, forming the component of an ultra-high-molecular-weight-polyethylene (UHMWPE) and a stiffening filler. A bracket and a running board assembly are also disclosed.