Overmolded Sheet Metal Structures with Integrated Attachments
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Solution Overview
Problem
Traditional vehicle body-in-white (BIW) members constructed from stamped and welded sheet metal panels lack integrated solutions for mounting additional components and effectively absorbing impact energy, leading to inefficiencies in impact energy management and increased part costs.
Innovation Solution
The integration of a reinforcing structure, including a rib structure and energy absorbing portion, molded onto both sides of a sheet metal panel, along with an integrally molded attachment structure such as weld nuts or brackets, to form a structurally reinforced vehicle body component that can absorb impact energy and securely attach additional components using a single-shot injection molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional stamped and welded sheet metal panels are used for BIW members, then structural strength is achieved, but the ability to absorb impact energy and mount additional components is insufficient
Solution Approach 1:
The patent combines multiple functions into a single integrated structure: the sheet metal panel, reinforcing ribs, energy-absorbing features, and attachment structures (such as weld nuts or tabs) are all formed as one unified component. This merging eliminates the need for separate mounting brackets and energy-absorbing elements, thereby providing both structural strength and adaptability for mounting additional components while maintaining crashworthiness.
Solution Approach 2:
The BIW member is designed to perform multiple functions simultaneously: it provides structural support, absorbs impact energy through integrated energy-absorbing features, and serves as a mounting platform for additional vehicle components via integrally formed attachment structures. This multi-functionality resolves the contradiction by making the single component adaptable to various mounting needs while maintaining its primary structural and safety functions.
2Stability of the object's composition
If traditional stamped and welded sheet metal panels are used for BIW members, then structural integrity is maintained, but impact energy absorption capability is insufficient
Solution Approach 1:
The patent incorporates energy-absorbing features directly into the BIW member structure before impact occurs. These pre-integrated features (such as collapsible ribs or deformable sections) are designed to activate during crash events, absorbing impact energy in a controlled manner while preserving the overall structural integrity of the member. This beforehand preparation resolves the contradiction by ensuring both integrity and energy absorption capability.
3Adaptability or versatility
If multiple separate components are used for BIW members with additional attachments, then mounting capability is improved, but part costs and manufacturing complexity increase
Solution Approach 1:
The patent merges the sheet metal panel, reinforcing structures, energy-absorbing features, and attachment structures into a single integrated component formed through one stamping and welding process. This consolidation reduces the total number of parts, simplifies manufacturing, and lowers assembly complexity while maintaining full mounting capability for additional vehicle components.
Solution Approach 2:
The integrated BIW member is designed to perform multiple functions within a single component: structural support, energy absorption, and versatile mounting capability. By incorporating universal attachment structures (such as weld nuts or tabs) that can accommodate various fastening methods and component types, the design achieves adaptability without increasing manufacturing complexity, as all features are formed in one integrated process.
4Ease of manufacture
If traditional BIW members are used, then manufacturing process is simple, but additional components cannot be securely mounted
Solution Approach 1:
The patent combines the attachment structures (such as weld nuts, tabs, or brackets) directly into the BIW member during the primary stamping and welding process. This integration ensures that mounting features are as reliably formed as the main structural elements, providing secure mounting capability without requiring separate manufacturing steps or additional assembly processes, thereby maintaining manufacturing simplicity while improving mounting reliability.
Data Source
AI summary
This disclosure details overmolded vehicle sheet metal structures that included integrated attachments for achieving part integration. An exemplary sheet metal structure includes a sheet metal panel, a reinforcing structure molded on the sheet metal panel, and an integrally molded attachment structure formed within the reinforcing structure. In some embodiments, the integrally molded attachment structure may include a nut, a bracket, or both. An additional vehicle component may be attached to the sheet metal panel via the integrally molded attachment structure. The sheet metal structure may be formed in a single shot injection molding process.