Hollow Profile Inserts for Vehicle Component Stiffness
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Solution Overview
Problem
Vehicle components like lift gates and front end modules face challenges in achieving high torsional and bending stiffness without increasing weight, which affects fuel efficiency and aesthetic quality, as traditional methods like injection molding and the use of steel or ribs lead to undesirable bending and potential deformation issues.
Innovation Solution
Incorporating a closed hollow profile insert into polymeric vehicle components, such as lift gates and front end modules, which provides enhanced torsion and bending stiffness while maintaining a lightweight design, and using a polymeric cover for aesthetic and thermal expansion purposes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional injection molding or steel inserts are used, then structural integrity is improved, but weight increases and fuel efficiency decreases
Solution Approach 1:
The patent employs composite construction by integrating a polymeric carrier with a closed-section hollow profile insert. This composite structure achieves high torsional and bending stiffness comparable to steel while maintaining the weight advantages of polymeric materials, directly resolving the contradiction between structural integrity and weight.
Solution Approach 2:
The closed-section hollow profile insert is strategically positioned within the carrier to provide localized reinforcement where torsional and bending stresses are highest. This allows the component to achieve high structural integrity only where needed, rather than uniformly throughout the entire component, thereby optimizing the strength-to-weight ratio.
2Stability of the object's composition
If panel thickness is increased or ribs are added, then torsional rigidity is improved, but weight increases and aesthetic quality deteriorates
Solution Approach 1:
The integration of the closed-section hollow profile insert within the polymeric carrier creates a composite structure that achieves high torsional rigidity without increasing overall component weight. The hollow profile acts as a structural reinforcement that is lighter than traditional rib additions or thickness increases.
Solution Approach 2:
The closed-section hollow profile utilizes curved, continuous geometry that inherently provides superior torsional rigidity compared to flat or ribbed structures. The circular or oval cross-section of the hollow profile efficiently resists twisting forces while maintaining a sleek, aesthetic appearance without visible imperfections.
3Stability of the object's composition
If ribs or steel inserts are used for reinforcement, then structural stability is improved, but aesthetic quality deteriorates due to visible imperfections
Solution Approach 1:
The patent merges the structural reinforcement function with the aesthetic outer panel by integrating the closed-section hollow profile insert within the polymeric carrier. The insert is completely enclosed, eliminating visible imperfections while providing the necessary structural stability, thus combining structural and aesthetic functions into a single seamless component.
Solution Approach 2:
The polymeric carrier acts as a thin-walled shell that encloses the hollow profile insert. This shell structure provides both aesthetic appearance and structural support, while the enclosed insert reinforces the structure without being visible, maintaining aesthetic quality while ensuring structural stability.
4Weight of moving object
If polymeric materials are used, then weight is reduced, but ability to accommodate stresses and strains deteriorates
Solution Approach 1:
The patent creates a composite structure where the polymeric carrier provides lightweight properties while the integrated closed-section hollow profile insert provides enhanced stress and strain resistance. This composite approach allows the component to maintain the weight advantages of polymeric materials while achieving the strength characteristics typically associated with metal reinforcements.
Solution Approach 2:
The closed-section hollow profile utilizes curved geometry that is inherently stronger and more resistant to stress concentration than flat or angular structures. The continuous curved walls of the hollow profile efficiently distribute and resist applied stresses and strains, enabling the polymeric component to accommodate higher loads without compromising weight savings.
Data Source
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AI summary
In an embodiment, a vehicle component for a vehicle can comprise: a carrier comprising a top portion (10), a bottom portion (12), a first side portion(14), and a second side portion (16); a cavity (18), wherein the cavity comprises a bottom cavity wall (17), cavity side walls (21, 23), and a top portion of the cavity having an upper cavity wall (19); an insert (24) covering at least a portion of the cavity and attached to the upper cavity wall the bottom cavity wall, and/or the cavity side walls; and an cover (44) attached to the carrier.