Unitary Fiber-Reinforced Plastic Side Panel Buckling Resistance
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Solution Overview
Problem
Existing side panel assemblies for automotive bodies, made of fiber-reinforced resins, face challenges in productivity and weight reduction due to their complex structure and susceptibility to buckling under compressive loads.
Innovation Solution
A unitary side panel with an open cross-sectional shape, comprising a side sill, roof rail, and pillar made of fiber-reinforced plastic, featuring recesses with thicker side walls and flanges to enhance buckling resistance and bending moment capacity, and a rib at the boundary between the side sill and front fender to distribute compressive loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a unitary side panel with open cross-sectional shape is used, then productivity is improved and weight is reduced, but buckling resistance deteriorates under compressive loads
Solution Approach 1:
The side panel incorporates localized structural features (recesses with thicker side walls and flanges) at specific positions along the panel length. These localized reinforcements increase buckling resistance without requiring the entire panel to be thicker or more complex, thus maintaining productivity benefits while addressing the strength deficiency in critical areas.
2Strength
If a closed hollow side panel assembly with multiple structural members is used, then buckling resistance is improved, but productivity deteriorates due to complex assembly
Solution Approach 1:
The invention merges multiple structural members (side sill, roof rail, pillar) into a single unitary side panel formed from one continuous piece of fiber-reinforced plastic. This integration eliminates the need for separate components and adhesive bonding operations, dramatically simplifying assembly and improving productivity while maintaining adequate buckling resistance through optimized cross-sectional geometry.
3Strength
If side walls of the recess are made thicker to increase buckling stress, then manufacturing complexity increases
Solution Approach 1:
The invention varies the wall thickness parameter along the length of the recess, with thicker sections positioned at the flanges and thinner sections in other areas. This non-uniform thickness distribution optimizes buckling stress at critical locations while minimizing overall material usage and molding complexity, achieving a balance between strength and manufacturability.
Data Source
AI summary
A side panel for an automotive body includes a unitary panel having a side sill, a roof rail, and a pillar integrally joined to each other. The pillar extends from the side sill to the roof rail, and each of the side sill, the roof rail, and the pillar are made of fiber-reinforced plastic. At least one of the side sill, the roof rail, and the pillar has a recess concave transversely outwardly relative to the automotive body. The recess has an opening that opens transversely inwardly relative to the automotive body. The recess is defined by two side walls bent from flanges and extending transversely outwardly relative to the automotive body, and a bottom wall joined to the side walls. The side walls have portions joined to the flanges, the portions of the side walls being thicker than the bottom wall.