UV-Cured Microtruss Insert for Vehicle Impact Beams
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Solution Overview
Problem
Existing vehicle impact beams face challenges in achieving low mass, high flexural stiffness, and strength while effectively absorbing energy during impacts, particularly due to limitations in material distribution and manufacturing complexity, especially in forming complex geometries and integrating energy absorption layers.
Innovation Solution
A method for fabricating a micro-truss structure within a thin support enclosure using UV light to polymerize a photomonomer resin, forming a micro-truss core with increased stiffness and strength, which is then integrated into an outer structural enclosure, allowing for precise spatial control and functional grading of mechanical properties, reducing manufacturing costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional impact beams use solid material construction, then strength and stiffness are achieved, but mass increases significantly
Solution Approach 1:
The patent employs foam core materials with controlled porosity to create a lightweight yet strong impact beam structure. The foam material provides structural integrity while maintaining low density, resolving the contradiction between strength and weight by utilizing the inherent properties of porous materials to achieve both high strength-to-weight ratio and energy absorption capacity
Solution Approach 2:
The patent uses composite construction combining different materials (such as aluminum alloy facesheets with foam core, or carbon fiber reinforced polymers) to achieve optimal balance between strength, stiffness, and weight. The composite structure allows each material to contribute its superior properties, creating an impact beam that is both lightweight and highly resistant to impact
2Loss of energy
If impact beams use complex geometric structures for energy absorption, then energy absorption capacity increases, but manufacturing complexity increases
Solution Approach 1:
The patent modifies material parameters such as foam density, cell structure, and composition to achieve varying energy absorption characteristics throughout the beam structure. By changing material parameters rather than geometric complexity, the patent achieves superior energy absorption while maintaining manufacturing simplicity
Solution Approach 2:
The patent divides the impact beam into distinct functional zones with different material properties - such as denser foam regions for high-energy absorption and lighter regions for weight reduction. This segmentation allows optimization of energy absorption in critical areas without unnecessarily complicating the overall structure
3Ease of manufacture
If material is distributed uniformly throughout the impact beam, then manufacturing is simplified, but structural efficiency decreases
Solution Approach 1:
The patent implements non-uniform material distribution with varying foam density, cell size, and material composition at different locations within the beam. Critical impact zones receive higher density or reinforced materials for maximum protection, while non-critical areas use lighter materials to reduce overall weight, achieving optimal structural efficiency
4Loss of energy
If energy absorption layers are integrated into the impact beam structure, then energy absorption improves, but manufacturing complexity increases
Solution Approach 1:
The patent combines the energy absorption function directly into the core foam material itself, eliminating the need for separate energy absorption layers. The foam core inherently provides both structural support and energy absorption through its cellular structure, merging multiple functions into a single integrated component that simplifies manufacturing
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 micro-truss core provides enhanced structural efficiency and reduced repair costs by enabling precise material placement, integrating energy absorption layers, and forming complex geometries not possible with traditional methods, while maintaining safety and reducing load transfer to occupants during impacts.
Implementation Method 1
light from at least one UV source is directed through apertures in a mask and through the at least one transparent wall into the enclosure so as to polymerize and at least partially cure columns of the resin therein to form polymerized struts
Data Source
AI summary
A method for fabricating a micro-truss structure having particular application for a vehicle impact structure. The method includes providing a thin support enclosure having a plurality of walls, where at least one of the walls is transparent to ultraviolet (UV) light. The support enclosure is filled with a liquid photomonomer resin and light from at least one UV source is directed through apertures in a mask and through the at least one transparent wall into the enclosure so as to polymerize and at least partially cure columns of the resin therein to form polymerized struts defining a micro-truss core in the enclosure that is secured to the walls. The support enclosure is then inserted into an outer structural enclosure.