Foldable Natural Fiber Substrates for Vehicle Components
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Solution Overview
Problem
Conventional vehicle components, such as glove box bins, made from low-density polypropylene require thick walls for structural integrity, leading to high area weights and inefficient packaging due to molded-in features that prevent stacking during shipping.
Innovation Solution
A foldable substrate comprising hingedly connected natural fiber-resin impregnated blank sections with a polymeric resin overmolded for added strength and aesthetics, featuring a hinge section with a fold-initiating groove for efficient folding and stacking, achieving a low area weight and significant weight savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick walls are used for structural integrity in low-density polypropylene components, then strength is improved, but area weight increases
Solution Approach 1:
The patent uses a composite structure combining natural fiber-resin impregnated blank sections with overmolded polymeric resin. The natural fiber-resin blank provides the base structure with adequate strength, while the overmolded polymeric resin is applied selectively to specific areas requiring enhanced strength or aesthetic appearance. This composite approach allows thin-walled construction overall while providing localized reinforcement, thereby reducing area weight while maintaining necessary structural integrity.
2Strength
If molded-in features are added to provide structural features, then strength is improved, but packaging efficiency deteriorates due to inability to stack
Solution Approach 1:
The patent divides the structural features into two categories: those integrated into the flat foldable substrate (maintaining stackability) and those added after folding through overmolding. The overmolded features are applied to the folded configuration rather than being molded into the flat substrate, allowing the substrate to be stacked efficiently in its flat state while still providing the necessary structural features in its final folded configuration.
Solution Approach 2:
The substrate is first formed with basic structural features in its flat state to enable stacking and shipping efficiency. Then, additional structural features and aesthetic features are added through overmolding after the substrate is folded into its final configuration. This preliminary action approach allows efficient packaging while still providing complete structural functionality.
3Weight of stationary object
If low-density materials are used to reduce weight, then area weight is improved, but structural integrity deteriorates requiring thicker walls
Solution Approach 1:
The patent employs a composite material system where the natural fiber-resin impregnated blank provides a lightweight base structure, and the overmolded polymeric resin provides localized strength enhancement. This allows the use of low-density materials overall while achieving necessary structural integrity through the combined properties of the composite system, avoiding the need for uniformly thick walls.
Solution Approach 2:
The overmolded polymeric resin is applied selectively to specific regions of the substrate where enhanced strength or aesthetic quality is required, rather than uniformly across the entire component. This local quality approach allows low-density materials to be used in non-critical areas while providing targeted reinforcement only where structurally necessary, optimizing the balance between weight and strength.
Data Source
Figure 1~2B
Figure 2C~2F
Figure 2G~2H
AI summary
Embodiments of foldable substrates and methods for making foldable substrates for a motor vehicle are provided herein. The foldable substrate (10) comprises a first wall (12) that has a first outer surface. The first wall (12) comprises a first natural fiber-resin impregnated blank section (22) that is overmolded with a first quantity of polymeric resin that forms at least a portion of the first outer surface. A second wall (14) has a second outer surface. The second wall (14) comprises a second natural fiber-resin impregnated blank section (22) that forms at least a portion of the second outer surface. The first and second walls (12, 14) are hingedly connected together.