Extruded Polymeric Reinforcements for Automotive Cavities
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Solution Overview
Problem
The high cost and inflexibility of molded polymeric parts for structural reinforcement due to the need for expensive tooling and molds, which limits their modification and application in lengthy cavities, especially in automotive vehicles.
Innovation Solution
The method involves extruding thermoplastic materials to form column structures with varying profiles and connecting them using a connector device, incorporating activatable materials and fibers like glass, Kevlar, or carbon, which can be heat-activated to provide reinforcement without injection molding, allowing for customization and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If molded polymeric parts are used for structural reinforcement, then substantial strength and lightweight properties are achieved, but high tooling and mold costs significantly increase production cost
Solution Approach 1:
The patent replaces expensive molded parts with extruded polymeric parts that can be manufactured at lower cost using extrusion processes. The extrusion process eliminates the need for costly molds and tooling, making the reinforcement structure more cost-effective while maintaining structural integrity
Solution Approach 2:
The patent changes the manufacturing process from molding to extrusion, fundamentally altering how the polymeric reinforcement is produced. This parameter change in the manufacturing process eliminates mold costs while maintaining the structural reinforcement properties through carefully designed extruded geometries
2Strength
If molded parts are used for structural reinforcement, then substantial strength is achieved, but any significant change to the profile requires new tooling for additional cost
Solution Approach 1:
The patent makes the reinforcement structure adaptable to different profiles by using extrusion processes that can easily modify geometries. The system transitions from fixed mold-based profiles to flexible extrusion-based profiles that can be adjusted without requiring new tooling, enabling dynamic adaptation to different structural requirements
Solution Approach 2:
The patent divides the reinforcement structure into multiple extruded columns with varying profiles that can be independently designed and connected. This segmentation allows different sections to have optimized profiles for specific structural needs while using the same extrusion process, providing versatility without requiring complete retooling
3Ease of manufacture
If extruded polymeric parts are used instead of molded parts, then cost-effective manufacturing and profile flexibility are achieved, but structural reinforcement strength must be maintained
Solution Approach 1:
The patent uses composite polymeric materials with reinforcing fibers (such as glass, carbon, or other high-strength fibers) embedded in the extruded columns. This composite structure maintains the cost and flexibility advantages of extrusion while achieving the structural reinforcement strength typically associated with molded parts
Solution Approach 2:
The patent employs curved and contoured extruded column profiles that optimize structural strength through geometric design. The extrusion process can create complex curved geometries that provide structural reinforcement comparable to molded parts while maintaining the cost and flexibility benefits of extrusion
4Adaptability or versatility
If extruded columns with varying profiles are used, then adaptability to complex cavity shapes is improved, but the complexity of connecting multiple columns increases
Solution Approach 1:
The patent develops universal connector devices that can accommodate multiple column profiles and configurations. These multi-functional connectors can join columns with varying profiles through standardized interfaces, reducing the complexity that would otherwise arise from custom connectors for each profile variation
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 approach enables lightweight, cost-effective structural reinforcement of cavities with extruded polymeric members that can be easily modified and adapted to fit complex shapes, offering substantial strength and flexibility without the need for expensive molds, suitable for lengthy applications in vehicles.
Implementation Method 1
extruding a thermoplastic material to form a first column structure having a first profile
Implementation Method 2
The activatable material may be heat activated. The activatable material is activated by heat entering within the one or more column structures through the one or more openings
Implementation Method 3
The thermoplastic material may form a tenacious bond with an exterior portion of one or more of the plurality of fibers
Data Source
AI summary
A polymeric insert formed by extruding a material including polyamide and a plurality of long fibers to form a column structure having a first profile. A method for making such an insert comprising passing a polymeric material in a substantially flowable state through a die, and substantially simultaneously passing a fiber through the die, wherein during the passing step the polymeric material has a relative viscosity of less than about 60 according to ASTM D789.