Hybrid BIW Panel with Molded Composite Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional body-in-white (BIW) panels constructed from stamped and welded sheet metal struggle to effectively manage and absorb impact energy due to limitations in load resistance and energy management during impact events, particularly in managing the size of the gap between structural components.
Innovation Solution
The integration of a reinforcing structure molded on the inboard side and an energy absorbing structure molded on the outboard side of the BIW member using overmolded plastic or composite materials, including ribbed designs such as straight, honeycomb, cellular, and bionic ribs, to enhance stiffness and absorb impact loads, while reducing the size of the gap between structural components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional stamped and welded sheet metal panels are used, then manufacturing simplicity is maintained, but impact energy absorption and load resistance are insufficient
Solution Approach 1:
The patent applies composite materials by combining sheet metal with molded plastic or composite materials to create a hybrid structure. The molded material is integrated with the metal panel through adhesive bonding, mechanical interlocking, or thermal bonding, forming a composite structure that leverages the strength of metal and the energy-absorbing properties of plastic/composite materials to improve impact energy absorption while maintaining manufacturing feasibility
Solution Approach 2:
The patent segments the BIW panel into multiple functional zones with different structural characteristics. Reinforcing structures with higher material density are placed in high-stress areas, while energy-absorbing structures with controlled density are positioned in impact zones. This segmentation allows optimized performance in different regions without uniformly increasing structural complexity across the entire panel
2Strength
If reinforcing structures are added to the BIW panel, then load resistance is improved, but weight increases
Solution Approach 1:
The patent applies local quality by varying the material density and structural characteristics of the molded reinforcing structures based on local stress requirements. Areas requiring higher load resistance receive denser or more substantial reinforcing structures, while areas with lower requirements use lighter configurations. This localized optimization improves load resistance where needed without uniformly increasing the weight of the entire panel
Solution Approach 2:
The use of composite materials allows for lightweight reinforcing structures that maintain high strength-to-weight ratios. The molded plastic or composite materials can be engineered with specific mechanical properties that provide adequate load resistance with less mass compared to traditional metal reinforcements, thereby improving load resistance while minimizing weight increase
3Loss of energy
If energy absorbing structures are molded on the BIW panel, then impact energy management is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the energy-absorbing function with the existing BIW panel manufacturing process by integrating molded structures directly onto the metal panel during assembly. The molded plastic or composite components are formed and attached in the same production line, combining structural reinforcement and energy absorption functions into a single integrated manufacturing step rather than requiring separate processes for each function
Solution Approach 2:
The patent utilizes parameter changes in the molding process, such as varying injection pressure, temperature, and material flow characteristics, to create energy-absorbing structures with controlled density and mechanical properties. By adjusting these parameters, the same molding process can produce structures with different energy-absorption characteristics without requiring fundamentally different manufacturing equipment or processes
4Stability of the object's composition
If the gap between structural components is reduced, then structural integrity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces adhesive bonding or mechanical interlocking features as intermediaries between the molded structures and the metal panel. These intermediary bonding mechanisms provide tolerance compensation, allowing for larger manufacturing tolerances in the molded components and metal panel while still achieving consistent, reliable gaps and strong structural integrity. The bonding layer acts as a buffer that absorbs dimensional variations
Data Source
AI summary
An apparatus, according to an exemplary aspect of the present disclosure includes, among other things, a body-in-white member having an inboard side and an outboard side, a reinforcing structure molded on the inboard side, and an energy absorbing structure molded on the outboard side. A method according to an exemplary aspect of the present disclosure includes, among other things, providing a body-in-white member having an inboard side and an outboard side, molding a reinforcing structure on the inboard side, and molding an energy absorbing structure on the outboard side.