Multi-Layer Foam Reinforcement in Hollow Vehicle Components

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Solution Overview

Problem

Current structural foam reinforcement processes require multiple forming stations and cycles to fill a single component, especially when different materials are used at various locations, leading to inefficiencies and increased complexity.

Innovation Solution

A process involving inflatable bladders is used to form multiple layers of structural foam reinforcements within a structural component. This process includes inserting bladders into hollow passages, inflating them to create cavities, filling these cavities with polymer resin, and foaming the resin to form structural reinforcement layers, which are then partially filling the cross-section of the component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple forming stations and cycles are used to fill different portions of a component with structural foam or different materials, then material distribution precision is improved, but device complexity and manufacturing time increase

Engineering Contradiction:

Improvematerial distribution precisionVSAvoidforming station complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The hollow passage is divided into multiple cavities using inflatable bladders that create internal partitions. Each cavity can be filled with different materials or foam densities independently, allowing precise material distribution throughout the component without requiring multiple forming stations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple bladders are nested within each other inside the hollow passage, with inner bladders creating additional cavities within the space defined by outer bladders. This nested configuration enables complex multi-material or multi-density foam structures to be formed in a single operation.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Manufacturing precision

Engineering Contradiction:

Improvematerial distribution precisionVSAvoidmanufacturing throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Multiple cavity formation and filling operations are merged into a single forming cycle. The bladders are inflated and all cavities are filled with appropriate materials simultaneously, eliminating the need for sequential operations at multiple forming stations and significantly improving manufacturing throughput.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bladders are positioned and inflated in advance to create the desired cavity configuration before material injection. This preliminary action ensures that all cavities are properly formed and ready for simultaneous filling, enabling complex multi-material structures to be produced in one operation.

Inventive Principle:

Principle #10Preliminary action

3Strength

If the entire cross-section of the hollow passage is filled with structural foam, then structural strength is improved, but weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidcomponent weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Different regions of the hollow passage are filled with foam or materials having different densities and mechanical properties. High-strength foam is placed in areas requiring structural support, while lower-density foam or air-filled cavities are used in non-critical areas, optimizing the strength-to-weight ratio of the overall component.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of filling the entire cross-section with heavy structural foam, the invention uses partial filling with strategically placed foam layers and air-filled cavities. This provides sufficient structural strength for the application while minimizing unnecessary material and weight.

Inventive Principle:

Principle #16Partial or excessive action

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

The process allows for the efficient formation of multiple structural reinforcement layers in a single component, reducing cycle time and weight by partially filling the cross-section, thereby improving manufacturing efficiency and vehicle performance.

Implementation Method 1

foaming the first polymer resin to form a first polymer resin foam

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

inflating the first bladder with a first fluid

Methodology Applied

Scientific EffectInflation: Pressure Increase

Data Source

PatentUS12208604B2Inflatables-based process for creating multi-layer internal reinforcements

Publication Date: 2025.01.28 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A structural component for a vehicle and a process and system for forming the structural component. A first cavity is formed in a first hollow passage between a first bladder and an interior surface of a component forming the structural component. A first structural reinforcement layer is formed in the first cavity by filling the first cavity with a first polymer resin and foaming the first polymer resin to form a first polymer resin foam. A second cavity is formed in the first hollow passage and a second structural reinforcement layer is formed in the second cavity by filling the second cavity with a second polymer resin and foaming the second polymer resin to form a second polymer resin foam.