Body Panel Reinforcement Sealer With Composite Skin to Prevent Dents

Solution Overview

Problem

Existing vehicle body panel sealers either have low flexural strength, resulting in weak rigidity, or high flexural strength, leading to increased hardness and dents on the outer panel, while also requiring thicker panels and additional members/brackets, which increase costs.

Innovation Solution

A sealer for body panel reinforcement comprising a sealer layer with a specific composition including epoxy resin, curing agent, adhesion imparting agent, filler, moisture absorbent, flow inhibitor, and stabilizer, combined with a skin layer of glass fiber reinforced plastic, optimized for thickness and fiber fineness and density to enhance rigidity without causing dents and reduce panel thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the sealer has high flexural strength to improve rigidity, then rigidity is improved, but hardness increases causing dents on the outer plate panel

Engineering Contradiction:

Improveflexural strengthVSAvoiddents on outer plate panel

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The sealer is divided into two distinct layers: a lower sealer layer providing flexibility and adhesion, and an upper skin layer with glass fiber reinforced plastic providing rigidity. This segmentation allows each layer to perform its specific function without causing dents, resolving the contradiction between strength and harmful effects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sealer uses a composite structure combining a polymer-based sealer layer with a glass fiber reinforced plastic skin layer. This composite material approach provides both the flexibility needed to prevent dents and the rigidity required for structural reinforcement, directly addressing the technical contradiction.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If the sealer has low flexural strength to prevent dents, then dents are reduced, but rigidity becomes weak

Engineering Contradiction:

Improvedents on outer plate panelVSAvoidrigidity

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The sealer is divided into two distinct layers: a lower sealer layer providing flexibility and adhesion, and an upper skin layer with glass fiber reinforced plastic providing rigidity. This segmentation allows each layer to perform its specific function without causing dents, resolving the contradiction between strength and harmful effects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sealer uses a composite structure combining a polymer-based sealer layer with a glass fiber reinforced plastic skin layer. This composite material approach provides both the flexibility needed to prevent dents and the rigidity required for structural reinforcement, directly addressing the technical contradiction.

Inventive Principle:

Principle #40Composite materials

3Strength

If panel thickness is increased to improve rigidity, then rigidity is improved, but manufacturing cost and complexity increase

Engineering Contradiction:

ImproverigidityVSAvoidpanel thickness

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The sealer uses a composite structure combining a polymer-based sealer layer with a glass fiber reinforced plastic skin layer. This composite material approach provides both the flexibility needed to prevent dents and the rigidity required for structural reinforcement, directly addressing the technical contradiction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the material parameters of the sealer by incorporating glass fiber reinforced plastic with specific fiber fineness (30-60 deniers) and density (60-80 threads), allowing thin panels to achieve high rigidity without increasing thickness, thus reducing manufacturing complexity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11833801B2Sealer for body panel reinforcement

Publication Date: 2023.12.05 HYUNDAI MOTOR CO LTD

AI summary

A sealer for body panel reinforcement includes a sealer layer on a panel for a vehicle body, and a skin layer disposed on the sealer layer and including glass fiber reinforced plastic.