Vehicle Cavity Reinforcement With Dual Expandable Carriers
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Solution Overview
Problem
Existing reinforcing elements for structural elements with cavities in vehicles face challenges in optimal connection and reinforcement due to limited surface area for attachment, leading to suboptimal sealing and reinforcement, especially in irregularly shaped cavities.
Innovation Solution
A device comprising two interconnected carriers with closed surfaces and ribs, each coated with expandable material, allowing extensive adhesive application for better connection to the structural element, and featuring mechanical connections for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a carrier element with M- or W-shaped cross section is used, then the carrier element can be easily extracted from the mould and produced by injection-moulding, but the carrier element cannot be connected optimally to the structural element due to insufficient attachment surfaces
Solution Approach 1:
The carrier element is divided into multiple segments (first carrier and second carrier) that are connected to each other. Each carrier has its own outer side with closed surface for attachment and inner side with ribbed surface. This segmentation allows each carrier to be easily extracted from the mould while providing sufficient total attachment surface area for optimal connection to the structural element, resolving the contradiction between ease of manufacture and connection quality.
2Device complexity
If the carrier element has limited surface area for adhesive application, then the carrier element structure is simple, but the connection to the structural element is suboptimal
Solution Approach 1:
The invention transitions from a single-carrier element to a multi-carrier system where carriers are connected in sequence. The first carrier connects to the structural element, and the second carrier connects to the first carrier, effectively adding a dimensional aspect to the attachment process. This increases the total attachment surface area available for adhesive application without significantly increasing the overall structural complexity, thereby improving connection quality while maintaining manufacturing simplicity.
3Adaptability or versatility
If irregularly shaped cavities are used, then the structural element design is flexible and adaptable, but sealing and reinforcement become difficult to implement properly
Solution Approach 1:
The carrier elements are designed with differentiated surface qualities: the outer side has a closed surface optimized for adhesive application to the structural element, while the inner side has a ribbed surface for connection between carriers. This local quality differentiation allows the carriers to adapt to irregular cavity shapes while maintaining reliable sealing and reinforcement through targeted adhesive application on the appropriate surfaces, resolving the contradiction between cavity shape flexibility and sealing effectiveness.
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 provides a robust and cost-effective means to reinforce and seal cavities by ensuring a larger attachment area and mechanically loadable connections, adapting to various cavity shapes.
Implementation Method 1
a first expandable material (4) is arranged at least partially on the closed surface of the outer side; a second expandable material (5) is arranged at least partially on the closed surface of the outer side; wherein the first expandable material and the second expandable material connect the carriers to walls of the structural element following expansion
Data Source
AI summary
Device for reinforcing a structural element in a motor vehicle, including: a first carrier which has an outer side with a mainly closed surface and an inner side with a surface defined mainly by ribs, wherein a first expandable material is arranged at least partially on the closed surface; a second carrier which has an outer side with a mainly closed surface and an inner side with a surface defined mainly by ribs, wherein a second expandable material is arranged at least partially on the closed surface; wherein the first and second carriers are connected together so the inner sides face one another; and wherein the outer sides are each directed towards a wall of the structural element in a state of use, so the first and the second expandable materials connect the carriers to walls of the structural element following expansion.