Activatable Material Carrier for Structural Reinforcement

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Solution Overview

Problem

Current methods for reinforcing structural members in the transportation industry, such as automotive vehicles, often require fasteners or adhesives for attaching activatable materials, which can increase manufacturing costs and assembly time.

Innovation Solution

A system comprising a carrier with integrated restrictors and activatable material that expands and adheres to structural member walls upon heat application, eliminating the need for fasteners or adhesives by restricting the material's movement during placement, thereby securing it without additional attachment features.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fasteners or adhesives are used for attaching activatable materials, then the structural reinforcement is achieved, but the manufacturing cost and assembly time increase

Engineering Contradiction:

Improvestructural reinforcementVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent extracts and eliminates the need for separate fasteners or adhesives by integrating the attachment function directly into the activatable material itself. The activatable material is designed to self-attach to the structural member upon activation, removing the disturbing part (separate attachment components) from the system and reducing assembly complexity and time.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The activatable material performs the attachment function itself without requiring external fasteners or adhesives. When activated, the material automatically bonds to the structural member, allowing the material to serve its own attachment needs and eliminating the need for separate attachment operations.

Inventive Principle:

Principle #25Self-service

2Strength

If fasteners or adhesives are used for attaching activatable materials, then the structural reinforcement is achieved, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural reinforcementVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent removes the need for separate fastener or adhesive components from the manufacturing process. By integrating the attachment function into the activatable material itself, the system eliminates additional parts and assembly steps, thereby reducing manufacturing complexity and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the reinforcement function and the attachment function into a single activatable material component. This merging of functions eliminates the need for separate fasteners or adhesives, reducing the number of parts and simplifying the manufacturing process, which directly lowers manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If activatable material is placed without restrictors, then the placement process is simpler, but the material movement and positioning accuracy deteriorate

Engineering Contradiction:

Improveplacement processVSAvoidmaterial positioning

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent introduces restrictors as intermediary elements between the activatable material and the carrier. These restrictors serve as a mediating structure that guides and constrains the material during placement, ensuring accurate positioning without complicating the overall placement process. The restrictors are integrated into the carrier design, maintaining ease of operation while achieving precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If restrictors are added to control activatable material, then the material positioning is improved, but the device complexity increases

Engineering Contradiction:

Improvematerial positioningVSAvoidcarrier structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the restrictors with the carrier structure to form an integrated unit. By combining the positioning function (restrictors) with the support function (carrier) into a single integrated component, the design achieves precise material positioning without significantly increasing overall device complexity. The restrictors are designed as integral features of the carrier rather than separate components.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach reduces manufacturing costs and assembly time by allowing for quick and inexpensive placement of activatable materials, forming a strong bond with structural members without the use of fasteners or adhesives, while providing effective reinforcement.

Implementation Method 1

The activatable material is configured to expand upon application of heat

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

adhere to the interior walls of the hollow structural member to provide reinforcement

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10589795B2Structural reinforcements

Publication Date: 2020.03.17 ZEPHYROS INC

AI summary

The present invention is predicated upon the provision of systems and methods for reinforcement of a structural member. More particularly, the present invention is predicated upon unique carrier configurations and application of reinforcing material thereto. In one configuration, the application of reinforcing material is achieved without the use of fasteners, adhesives, or both, for placement, locating and restrictive movement of the reinforcing material onto the carrier.