Exposed Structural Corner Reinforcement for Vehicle Joints

Solution Overview

Problem

Conventional welding methods for assembling and reinforcing vehicle joints are time-consuming, labor-intensive, and prone to human error, leading to inconsistencies and increased costs in high-throughput manufacturing processes.

Innovation Solution

A structural reinforcement system comprising a first and second wall with spacer legs defining channels, where a curable adhesive is applied within the channels or on the walls, and optionally a third wall is included to provide additional support, allowing for faster and more standardized joint reinforcement without welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to reinforce vehicle joints, then joint strength is improved, but labor costs and cycle time increase

Engineering Contradiction:

Improvejoint strengthVSAvoidcycle time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using a structural reinforcement component that attaches to the joint via fasteners. This substitution eliminates the time-consuming welding process while maintaining joint strength through mechanical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The structural reinforcement component is pre-fabricated with attachment features (such as fastener holes or mounting structures) before installation. This preliminary preparation allows for rapid installation at the joint without requiring complex on-site assembly, thereby reducing cycle time while ensuring proper alignment and strength.

Inventive Principle:

Principle #10Preliminary action

2Strength

If welding is used to reinforce vehicle joints, then joint strength is improved, but labor costs increase

Engineering Contradiction:

Improvejoint strengthVSAvoidlabor costs

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using a structural reinforcement component that attaches to the joint via fasteners. This substitution eliminates the time-consuming welding process while maintaining joint strength through mechanical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The structural reinforcement component is designed to be self-aligning and self-securing through its integrated attachment features. The component includes pre-formed mounting structures that automatically align with corresponding features on the joint, reducing the need for skilled welders and manual adjustment, thereby lowering labor costs.

Inventive Principle:

Principle #25Self-service

3Strength

If welding is used to reinforce vehicle joints, then joint strength is improved, but manufacturing consistency deteriorates due to human error

Engineering Contradiction:

Improvejoint strengthVSAvoidjoint reinforcement consistency

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using a structural reinforcement component that attaches to the joint via fasteners. This substitution eliminates the time-consuming welding process while maintaining joint strength through mechanical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The structural reinforcement component is pre-fabricated with attachment features (such as fastener holes or mounting structures) before installation. This preliminary preparation allows for rapid installation at the joint without requiring complex on-site assembly, thereby reducing cycle time while ensuring proper alignment and strength.

Inventive Principle:

Principle #10Preliminary action

4Strength

If welding is used to reinforce vehicle joints, then joint strength is improved, but manufacturing throughput decreases

Engineering Contradiction:

Improvejoint strengthVSAvoidmanufacturing throughput

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using a structural reinforcement component that attaches to the joint via fasteners. This substitution eliminates the time-consuming welding process while maintaining joint strength through mechanical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The structural reinforcement component is pre-fabricated with attachment features (such as fastener holes or mounting structures) before installation. This preliminary preparation allows for rapid installation at the joint without requiring complex on-site assembly, thereby reducing cycle time while ensuring proper alignment and strength.

Inventive Principle:

Principle #10Preliminary action

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 structural reinforcement system significantly reduces labor costs and cycle time, enhances manufacturing throughput, and provides consistent joint reinforcement by utilizing a curable adhesive that can be quickly applied and cured, eliminating the need for welding.

Implementation Method 1

The structural reinforcement may comprise a curable adhesive. The curable adhesive may be disposed in the first channel, the second channel, or both.

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The curable adhesive may be a heat-activated epoxy.

Methodology Applied

Scientific EffectThermal activation: Heating

Implementation Method 3

The curable adhesive may be a heat-activated epoxy.

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS12214827B2Exposed structural corner reinforcement

Publication Date: 2025.02.04 ZEPHYROS INC

AI summary

The present teachings generally relate to a structural reinforcement, a body member comprising the structural reinforcement, and a method of using the structural reinforcement. The structural reinforcement comprises a first wall, a second wall extending from a first side of the first wall. Spacer legs extend from a second side of the first wall and define a first channel Spacer legs extend from a second side of the second wall and define a second channel. The structural reinforcement is configured to reinforce a joint.