Vehicle Node Structure with Internal Safety Cable and Spiral Support Band
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Solution Overview
Problem
Existing vehicle body node structures lack improved crash properties, which are crucial for safety and injury reduction in vehicle accidents.
Innovation Solution
A node structure featuring at least two hollow profile components connected by a safety cable and a spirally wrapped support band, with the safety cable and support band working together to prevent further damage and stabilize the components during a crash, and the use of fiber-reinforced plastic materials for enhanced strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hollow profile components are connected by conventional means without safety cables, then the node structure is simpler and easier to manufacture, but the crash properties and safety are insufficient
Solution Approach 1:
The safety cable is threaded through the hollow interior of the profile components, nesting the cable within the existing structural elements. This integration approach adds safety functionality without significantly increasing external complexity or requiring additional mounting space.
Solution Approach 2:
The safety cable is pre-installed through the profile components before the final connection node assembly. This preliminary action ensures that the cable is properly positioned and tensioned before the crash event occurs, enabling immediate safety response when needed.
2Strength
If safety cables and support bands are added to improve crash properties, then the load-bearing capacity and safety increase, but the manufacturing complexity and production time increase
Solution Approach 1:
The safety system is divided into distinct modular components: the safety cable running through the profiles and the separate support bands wrapped around connection nodes. This segmentation allows each component to be manufactured and prepared independently, then assembled into the final node structure, simplifying the overall manufacturing process.
Solution Approach 2:
The support bands are applied with specific spiral wrapping parameters and tension levels to optimize their load-bearing capacity. By controlling the wrapping angle, number of turns, and tension force, the manufacturing process achieves consistent high-strength properties while maintaining procedural efficiency.
3Weight of moving object
If fiber-reinforced plastic materials are used for hollow profile components, then the weight is reduced, but the crash resistance and structural integrity may be compromised
Solution Approach 1:
The node structure combines fiber-reinforced plastic profile components with metal safety cables and support bands. This composite material approach leverages the weight advantages of fiber-reinforced plastics while incorporating the high strength and ductility of metal elements to ensure adequate crash resistance and structural integrity.
Solution Approach 2:
The support bands are applied in spiral wrapping patterns around the connection nodes, creating curved reinforcement paths that distribute crash forces more effectively. The spiral geometry provides multi-directional strength enhancement, improving crash resistance while maintaining the lightweight fiber-reinforced plastic profile components.
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 node structure effectively holds hollow profile components together during a crash, reducing the risk of injury and increasing the load-bearing capacity while maintaining a lightweight design.
Implementation Method 1
at least two of its hollow profile components are connected by at least one safety cable running in the interior and extending through the connecting node
Implementation Method 2
at least one of the hollow profile components is provided with a spirally wrapped support band
Implementation Method 3
at least one of the hollow profile components is made of fiber-reinforced plastic (FRP) or a fiber-reinforced plastic material
Data Source
Figure 1~2b
Figure 3a~3c
AI summary
The invention relates to a node structure (110) for a vehicle body, comprising at least two hollow profile components (120, 130, 140, 150) and a connecting node (160) that joins the hollow profile components (120, 130, 140, 150) at the node-side profile ends. At least two of the hollow profile components (120, 150) are connected by at least one internal safety cable (180) extending through the connecting node (160), and/or at least one of the hollow profile components is provided with a spirally wound support band. The invention further relates to a method for manufacturing such a node structure (110), a frame (body frame) with at least one such node structure (110), and a method for manufacturing such a frame.