3D Overmolded Reinforcement for Stiff Large Panels
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Solution Overview
Problem
Conventional reinforcement methods for large panels, such as liftgate panels, fail to meet structural performance requirements, are costly, and require secondary operations, while existing materials like steel and aluminum are heavy and expensive.
Innovation Solution
A three-dimensional (3D) reinforcement shape combined with an overmolding process that eliminates the need for secondary operations and reduces mass and cost, using a 3D geometry that can be pre-assembled or assembled in the injection tool, with metal reinforcements that are partially or fully overmolded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional flat metal brackets are used for reinforcement, then structural performance requirements are met, but the brackets exhibit creep and lower stiffness
Solution Approach 1:
The patent transitions from flat 2D metal brackets to three-dimensional shaped reinforcements with complex geometries including hollow sections, ribs, and contours. This dimensional change enables the reinforcement to resist creep and improve stiffness while maintaining structural performance requirements for large panels.
2Strength
If stamping steel or metal is used for reinforcement, then structural strength is achieved, but material waste occurs and the components are heavier
Solution Approach 1:
The patent changes the material parameter from traditional stamped metal to thermoplastic materials that can be injection molded into complex three-dimensional shapes. This enables achievement of required structural strength with reduced weight and eliminates material waste associated with stamping processes.
3Strength
If steel, aluminum, or magnesium castings are used for reinforcement, then performance requirements are fulfilled, but the cost is much higher and secondary operations are required
Solution Approach 1:
The patent merges the reinforcement component with the panel manufacturing process through overmolding. The three-dimensional reinforcement is embedded directly into the panel during injection molding, eliminating the need for separate casting, assembly, and secondary operations required by traditional metal reinforcement methods.
4Stability of the object's composition
If known hollow tubes are used for stiffening, then stiffness is improved, but the tubes collapse during processing
Solution Approach 1:
The patent creates a composite structure where thermoplastic material forms a protective shell around hollow reinforcement tubes. This composite construction prevents tube collapse during processing while maintaining the stiffness benefits of the hollow geometry, solving the reliability issue of known hollow tube stiffening methods.
Data Source
AI summary
A three-dimensional overmolding and process for manufacturing same. The three-dimensional overmolding has a three-dimensional structure with overmolding, which gives significant performance benefits. Assembly and joining of reinforcements is done before the overmolding or in the injection molding tool. The three-dimensional overmolding meets predetermined structural requirements without requiring secondary operations and at a lower mass and cost. The structural benefits are due to the three dimensional shape in combination with the benefit of the overmolding process.