Expandable Polymer Bulkhead Reinforcement for Vehicle Cavities
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Solution Overview
Problem
Current reinforcement methods for vehicle structures, such as those using sheet metal bulkhead support members in hollow cavities, are labor-intensive and require extensive secondary processing to fit different vehicle cavities, leading to increased weight and time in reinforcement.
Innovation Solution
A structural reinforcement device comprising a first and second reinforcement section with projections and apertures for expandable polymeric material, which expands and cures to couple the sections without additional local reinforcement components, allowing for a tunable spine structure that adapts to various cavity shapes without secondary processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sheet metal bulkhead support members are used to reinforce vehicle structures, then structural strength is improved, but manufacturing complexity and labor intensity increase due to extensive secondary processing
Solution Approach 1:
The reinforcement device is divided into multiple sections (first reinforcement section, second reinforcement section, third reinforcement section) that can be separately manufactured and then assembled together. Each section contains cavities and projections that facilitate modular construction, eliminating the need for complex secondary processing of single-piece bulkheads.
Solution Approach 2:
The reinforcement device utilizes nested cavities and projections where projections from one section fit into cavities of adjacent sections. This nesting mechanism allows multiple reinforcement elements to be integrated into a unified structure through simple insertion, reducing manufacturing complexity while maintaining structural integrity.
2Strength
If traditional bulkhead reinforcement methods are employed, then structural support is provided, but assembly time and processing time increase due to labor-intensive procedures
Solution Approach 1:
The reinforcement sections are pre-formed with integrated cavities and projections during the primary manufacturing process. The expandable material is pre-positioned within the cavities before assembly, eliminating the need for time-consuming secondary operations during final assembly. This preliminary preparation significantly reduces assembly time while maintaining structural support capabilities.
3Strength
If multiple stampings and local reinforcement components are used, then reinforcement effectiveness is improved, but device complexity and material usage increase
Solution Approach 1:
The invention merges the functions of multiple separate reinforcement components into a single integrated reinforcement device. The multiple sections with interconnected cavities and projections create a unified structure that provides comprehensive reinforcement without requiring additional local reinforcement components, thereby reducing device complexity while maintaining effectiveness.
4Stability of the object's composition
If expandable material is used to couple reinforcement sections, then structural stability is improved, but processing requirements increase
Solution Approach 1:
The expandable material undergoes a parameter change from a compact state to an expanded state during assembly. This phase change allows the material to fill cavities and bond reinforcement sections together, creating a stable integrated structure. The processing requirement is simplified because the expansion occurs automatically under controlled conditions, eliminating complex fastening or bonding operations.
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
This method reduces the weight and time required for reinforcement by eliminating the need for additional processing and materials, providing support and stabilization for all cavity walls with an adhesive bond, and allows for efficient manufacturing of common carriers for different vehicle applications.
Implementation Method 1
the expandable material is a thermally expandable material that, upon exposure to heat at a predetermined temperature, expands and flows through the aperture
Implementation Method 2
where it will remain upon curing of the material, thereby causing the first reinforcement section to be coupled with the second reinforcement section
Data Source
AI summary
A structural reinforcement device for insertion into a cavity of a structure and method for making the same including a first reinforcement section that has at least one projection of a first expandable polymeric material secured to it; and a separate second reinforcement section mated with the first reinforcement section, the second reinforcement section being configured to include at least one cavity, into which the at least one projection penetrates upon mating, and at least one aperture defined therein through which the expandable material flows during expansion and where it will remain upon curing of the material, thereby causing the first reinforcement section to be coupled with the second reinforcement section.