Vehicle Panel Assembly Thermal Deformation Absorption
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Solution Overview
Problem
Vehicle panel assemblies made of different materials with varying coefficients of thermal expansion experience deformation issues due to temperature changes, leading to structural integrity problems and potential separation of panels.
Innovation Solution
Incorporating deformation absorption panels with a bent cross-section and slit holes, which are fitted and coupled to the external and internal panels using fastening members, to absorb thermal expansion differences in multiple directions, maintaining the initial form of the panel assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the external panel is made of synthetic resin material to reduce weight, then the weight of the door assembly and vehicle is reduced, but the coefficient of thermal expansion difference between external and internal panels causes thermal deformation
Solution Approach 1:
The invention introduces a deformation absorption panel as a separate component between the external panel and internal panel. This panel is divided into a first deformation absorption panel connected to the external panel and a second deformation absorption panel connected to the internal panel, creating segmented deformation absorption zones that can independently accommodate thermal expansion differences.
Solution Approach 2:
The deformation absorption panel utilizes parameter changes through its slit holes that expand and contract in response to temperature variations. The slit holes are configured to change their dimensions dynamically, allowing the panel to absorb thermal deformation through controlled geometric parameter changes rather than material property changes.
2Weight of moving object
If different materials with different coefficients of thermal expansion are used for external and internal panels, then weight reduction is achieved, but crack and breakage occur in the bonded portion due to accumulated deformation
Solution Approach 1:
The deformation absorption panel serves as an intermediary component between the external panel and internal panel. It mediates the thermal expansion mismatch by absorbing differential movements through its slit hole structure, preventing direct stress transmission to the bonded portions and thereby protecting the adhesive bonds from crack and breakage.
Solution Approach 2:
The invention implements beforehand cushioning by pre-configuring the deformation absorption panel with slit holes that are designed to expand and contract in advance of potential damage to the bonded portions. This proactive deformation absorption mechanism cushions the thermal stresses before they can accumulate to critical levels that would cause bond failure.
3Shape
If the door assembly is deformed due to thermal expansion differences, then the initial form is not maintained, but adding deformation absorption panels increases device complexity
Solution Approach 1:
The deformation absorption panel functions as a flexible structural element with slit holes that can bend and deform elastically. The slit hole configuration allows the panel to flex in controlled manner, maintaining the overall shape of the door assembly while accommodating local thermal deformations through the flexible slit structure.
Solution Approach 2:
The invention addresses thermal deformation in multiple dimensions by configuring slit holes in different orientations and patterns across the deformation absorption panel. The first and second deformation absorption panels handle deformations in different directional dimensions, comprehensively maintaining the door assembly's initial form through multi-dimensional deformation compensation.
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
Effectively compensates for the thermal expansion differences between external and internal panels, preventing deformation-induced separation and maintaining the structural integrity of the panel assembly across temperature changes.
Implementation Method 1
a coefficient of thermal expansion of the external panel and a coefficient of thermal expansion of the internal panel are different such that an amount of deformation of the external panel and an amount of deformation of the internal panel are different even according to a change in the same temperature
Implementation Method 2
Since an amount of contraction of the external panel is greater than amount of contraction of the internal panel in the winter, the door assembly is deformed in the opposite direction thereof
Data Source
AI summary
A panel assembly for a vehicle made of different materials with different coefficients of thermal expansion according to various exemplary embodiments of the present invention includes: an external panel 10, an internal panel 20 having the circumference bonded to the circumference of the external panel 10, and made of a material having a coefficient of thermal expansion different from a coefficient of thermal expansion of the external panel 10, and at least one deformation absorption panel 30, 40 connected to at least one of the external panel 10 and the internal panel 20 on the circumferences of the external panel 10 and the internal panel 20, and for absorbing an amount of thermal deformation according to a change in temperatures of the external panel 10 and the internal panel 20 when the external panel 10 and the internal panel 20 are thermally deformed.