Automotive Composite Panel Piercing Before Solidification
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Solution Overview
Problem
The existing method for manufacturing composite panels for automotive vehicle equipment, which involves piercing through holes for attachment elements, weakens the mechanical strength of the panels by cutting fibers and requires significant operator time and high accuracy.
Innovation Solution
A method where a piercing element with a pointed end is used to create through holes in the skin before solidification, displacing fibers to the periphery and allowing the matrix to solidify around it, and an insert is introduced during piercing to reinforce the hole, ensuring mechanical resistance and reducing fiber damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If piercing is performed after manufacture to create through holes, then attachment elements can be introduced, but the mechanical strength is weakened due to fiber cutting
Solution Approach 1:
The piercing element creates through holes in the skin before the polymer matrix solidifies, when the material is still in a moldable state. This preliminary action allows the piercing to occur without cutting hardened fibers, thus maintaining mechanical strength while enabling subsequent attachment element installation.
Solution Approach 2:
The patent changes the physical state parameter of the polymer matrix from solid (after solidification) to fluid/moldable (before solidification) at the time of piercing. This parameter change allows the piercing element to displace rather than cut fibers, resolving the contradiction between creating through holes and maintaining mechanical strength.
2Ease of operation
If piercing is performed after manufacture, then through holes can be created, but significant operator time and high piercing accuracy are required
Solution Approach 1:
The piercing operation is merged with the molding process by performing piercing before the polymer matrix solidifies. This combination eliminates the need for a separate post-manufacturing piercing step, reducing operator time and simplifying the overall process while maintaining accuracy through the mold's built-in piercing element.
3Ease of operation
If piercing is performed after manufacture, then through holes can be created, but the process requires high piercing accuracy
Solution Approach 1:
The piercing element is integrated into the mold structure and performs piercing during the molding process itself. This preliminary action benefits from the mold's inherent precision and stability, eliminating the need for high-precision manual piercing operations while ensuring accurate through hole placement.
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 method produces mechanically resistant through holes with reduced fiber damage and operator time, enhancing the mechanical strength and accuracy of the assembly process.
Implementation Method 1
solidification of the first skin in the molding cavity defined by the first half-mold and the second half-mold
Implementation Method 2
the piercing element displaces the fibers contained in the matrix to the periphery of the piercing element
Data Source
AI summary
A manufacturing method for an automotive vehicle component that includes the steps of: arranging at least a first skin capable of solidifying on a first half-mold of a mold; closing a second half-mold of the mold to form the first skin; then solidifying the first skin in the molding cavity defined between the first half-mold and the second half-mold. The second half-mold has a piercing element with at least one point-shaped end, and the method includes piercing by the piercing element of at least one through-hole in the first skin before solidification of the first skin.