Automotive Door Reinforcement with Adhesive Composite Sandwich Panel
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Solution Overview
Problem
Existing solutions for preventing motor vehicle doors from untimely opening during a side impact, such as deformations caused by sheet metal bending, are either aesthetically unpleasing or technically inefficient, as they lack sufficient stiffness.
Innovation Solution
A reinforcing device with a sandwich plate composed of composite materials glued to the inner part of the door panel, featuring a rigid profile that enhances stiffness without the need for welding, allowing the profile to be held securely without compromising the door's exterior appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a stamped concave shape aperture control is arranged to prevent deformation, then the door's resistance to deformation improves, but the aesthetic appearance deteriorates
Solution Approach 1:
The aperture control is divided into two functional parts: an aesthetic outer cover that maintains the door's appearance and an inner rigid structure that provides deformation resistance. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
The rigid inner structure is nested within the aesthetic outer cover, creating a layered configuration where the inner structure provides structural support while the outer cover maintains aesthetic appearance. This nested arrangement resolves the contradiction between strength and appearance.
2Ease of manufacture
If a sandwich plate of composite materials is added to reinforce the door, then the ease of manufacture improves, but the stiffness and deformation resistance deteriorate
Solution Approach 1:
The invention uses a composite structure combining a metallic rigid profile with adhesive layers and sandwich plate material. This composite approach provides the necessary stiffness and strength while maintaining ease of manufacture through adhesive bonding rather than complex mechanical fastening.
Solution Approach 2:
Instead of uniformly reinforcing the entire door panel, the rigid profile is strategically positioned only in the critical area around the aperture control where deformation resistance is most needed. This localized reinforcement maintains overall stiffness while minimizing material usage and preserving manufacturing simplicity.
3Strength
If welding is used to attach the rigid profile, then the strength of attachment improves, but the aesthetic appearance deteriorates
Solution Approach 1:
The invention replaces the mechanical welding process with an adhesive bonding system. The adhesive provides sufficient attachment strength while remaining invisible or minimally visible, thus preserving the aesthetic appearance of the door panel while maintaining strong attachment of the rigid profile.
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 effectively limits deformation and prevents the handle from being propelled by sheet metal folds, providing adequate protection while maintaining the door's aesthetic appeal and structural integrity.
Implementation Method 1
a reinforcing device with a sandwich plate composed of sheets of composite materials glued to an inner part of the outer panel, the device is characterized in that the reinforcement comprises a rigid section glued to the sandwich plate of composite materials
Data Source
Figure 1
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AI summary
The present invention relates to a door (1) comprising an outer panel (10), a control (2) for opening and a device for reinforcing an automotive door with an adhesive sandwich panel (3) made up of sheets of composite materials which is intended to be bonded to an interior part of the outer panel (10), the device is characterized in that it comprises a rigid section piece (4) bonded to the composite sandwich panel (3). The section piece (4) reinforces the sandwich panel (3) and the adhesive nature of the panel (3) allows the section piece (4) to be held in place without requiring any welding that would have a negative effect on the exterior appearance of the door.