Plastic Composite Panel Structure for Undercut-Free Molding
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Solution Overview
Problem
The existing manufacturing methods for plastic composite material panels used in purpose-built vehicles often result in bent shape portions being caught in molds, leading to difficulties in removing the panels smoothly and potentially reducing the cross-section of the vehicle body frame.
Innovation Solution
A plastic composite material panel design featuring an outer plate portion bonded to a vehicle body frame with a material filling portion thicker than the outer plate, and integrated bonding flanges, along with a manufacturing method using gel-type plastic composite material and movable dies to mold the panel without undercuts, allowing for easy extraction and increased moldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bent shape portion (undercut portion) is formed in the plastic composite material panel, then the panel can be bonded to the vehicle body frame, but the bent shape portion is caught in the molding part of the mold and cannot be smoothly taken out
Solution Approach 1:
The panel is divided into two distinct portions: an outer plate portion that provides the bent shape for bonding, and a material filling portion that is thicker and forms a substantial body. This segmentation allows the outer plate to be shaped for bonding purposes while the material filling portion provides a solid core that can be easily extracted from the mold without being caught by the bent portions.
Solution Approach 2:
The invention introduces a dimensional distinction between the outer plate portion (thin, bent) and the material filling portion (thick, substantial). By adding this thickness dimension to the material filling portion, the panel achieves both the bonding capability of bent shapes and the extractability of a substantial body that doesn't get caught in mold features.
2Strength
If the plastic composite material panel is designed with sufficient thickness for bonding, then bonding strength is improved, but the cross-section of the vehicle body frame is reduced
Solution Approach 1:
The panel implements local quality by having different thickness characteristics in different portions: the outer plate portion is thin and provides the bonding surface, while the material filling portion is thicker and provides structural support and bonding area without requiring the entire panel cross-section to be thick. This localized thickness distribution maintains bonding strength while preserving the vehicle body frame's cross-sectional area.
Data Source
AI summary
An embodiment plastic composite material panel includes an outer plate portion bent in a predetermined shape and configured to be bonded to a vehicle body frame through an adhesive, and a material filling portion integrally formed with the outer plate portion, the material filling portion being thicker than the outer plate portion.