Vehicle Support Chassis Reinforcement via Nested Element
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Solution Overview
Problem
Existing vehicle supports, such as transmission carriers, require increased bending stiffness while maintaining low additional costs and minimal manufacturing cost increments, which current steel metal plate components fail to achieve effectively.
Innovation Solution
Incorporating a reinforcing element along the longitudinal extension of the support with a separation layer for a positive and/or material fit connection, enhancing bending stiffness without significant weight increase, using conventional supports as base bodies and connecting via welding or mechanical means like clinching or riveting, allowing for modular design and varied material selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing element is added to increase bending stiffness, then the bending resistance is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The reinforcing element is inserted into the longitudinal extension of the support, nesting one structural element within another. This allows the reinforcing element to be positioned inside the existing support structure, increasing bending stiffness without adding significant external volume or weight. The reinforcing element fits within the longitudinal extension, creating a nested configuration that maximizes structural efficiency.
Solution Approach 2:
The support system combines two different elements: the base support structure and the inserted reinforcing element. These elements work together as a composite system, where the reinforcing element provides additional bending resistance while the separation layer enables their combination. The composite structure achieves higher overall stiffness than either element alone would provide.
2Strength
If a reinforcing element is added to increase bending stiffness, then the bending resistance is improved, but the manufacturing cost increases
Solution Approach 1:
The support system is divided into separate components: the base support and the reinforcing element. This segmentation allows each component to be manufactured independently using standard processes, then assembled together. The separating layer facilitates this modular construction, enabling the reinforcing element to be added without requiring complete remanufacturing of the original support structure.
Solution Approach 2:
The separating layer acts as an intermediary element between the base support and the reinforcing element. It enables the connection of these two components while managing the interface between them, allowing for standardized manufacturing processes for each component while facilitating their assembly into a reinforced structure.
3Strength
If the support structure is modified to increase stiffness, then the bending resistance is improved, but the structural complexity increases
Solution Approach 1:
The reinforcing element is nested within the longitudinal extension of the support, creating a compact integrated structure. This nesting approach increases stiffness without adding external complexity, as the reinforcing element is contained within the existing structural envelope rather than adding external attachments or modifications.
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 significantly increases bending resistance with minimal additional weight and cost, utilizing simple process technologies, and allows for corrosion protection through the separation layer, ensuring no unprotected surfaces remain, especially for corrosion-prone materials like steel.
Implementation Method 1
A separation layer is arranged between the reinforcing element and the surface of the support. This separation layer spaces the reinforcing element from the surface of the support.
Implementation Method 2
The connection in a positive and/or material fit manner to the support can be achieved, by welding, where welding spots produced at intervals are preferable
Implementation Method 3
or also by mechanical connection elements, such as clinching or riveting. In the case of clinching or rivets also, the tension- and shear-resistant connection of the reinforcing element to the support is carried out at spaced connection spots
Data Source
AI summary
The invention relates to a support (2, 3) used as a vehicle component and comprising a longitudinal extension which corresponds to a multiple of the transverse extension thereof. Said support (2, 3) comprises a reinforced transverse profile section. For this purpose, the support (2, 3) comprises at least one reinforced element (7, 8) which follows the longitudinal extension of the support (2, 3), is connected to the support in a positive and material fit manner and in a tension and shear-resistant manner, with the insertion of a separation layer (12) between the longitudinal extension of the support (2, 3).