Composite Reinforcement Insert with Overmolding Notches
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Solution Overview
Problem
Existing solutions for reinforcing tailgate linings in vehicles with composite plastic materials are not entirely satisfactory in terms of mechanical anchoring, as they face industrial difficulties in achieving robust retention between the bodywork part and the reinforcement insert, particularly with composite inserts.
Innovation Solution
A reinforcing element made of composite plastic material with overmoulding mechanical anchoring notches, such as flared notches and a bearing surface, is integrated into the bodywork part to enhance mechanical anchoring, where the notches are designed to oppose separation movements and the plastic material encapsulates the insert, improving retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sheet metal reinforcing elements are used with encapsulation, then mechanical reinforcement is achieved, but mechanical anchoring is insufficient
Solution Approach 1:
The reinforcing element is segmented into multiple zones: a central reinforcement zone and peripheral anchoring zones with notches. This segmentation allows the element to simultaneously provide structural reinforcement and mechanical anchoring through the plastic material that flows into the notched zones during overmolding.
Solution Approach 2:
The invention uses composite plastic material (thermoplastic or thermosetting resin with mineral fillers and/or reinforcing fibers) for the reinforcing element, combining the benefits of plastic material adaptability with enhanced mechanical properties for both reinforcement and anchoring functions.
2Reliability
If passage holes are created for mechanical retention, then anchoring is improved, but industrial manufacturing becomes difficult with composite inserts
Solution Approach 1:
The notches for mechanical anchoring are pre-formed as integral features of the reinforcing element during its manufacturing process. This preliminary action eliminates the need for subsequent hole-drilling or passage creation operations, simplifying industrial manufacturing while ensuring consistent anchoring quality.
Solution Approach 2:
The notch geometry parameters (depth, width, flaring angle) are optimized to provide effective mechanical anchoring while being compatible with composite plastic material processing. The notches are designed to be filled by plastic material flow during overmolding, transforming the material state to achieve retention without requiring through-holes.
3Reliability
If encapsulation is performed on the periphery, then mechanical blocking is achieved, but retention robustness is insufficient
Solution Approach 1:
The reinforcing element features local quality variations: the central zone provides uniform reinforcement, while the peripheral zones incorporate notches with specific geometries (flared shapes, varying depths) to enhance mechanical anchoring. This local differentiation optimizes both blocking and retention robustness in their respective zones.
Data Source
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AI summary
The invention relates to a reinforcement element (100) for a body part (200) made of composite plastic, forming an insert suitable for being at least partially overmolded into the body part (200), the reinforcement element (100) comprising a wall (300) delimited by a contour (330). The reinforcement element (100) is made of composite plastic, and at least a portion of the contour (330) has notches (400) for mechanical overmolding anchorage.