Patterned Panel Stiffener for Thin Sheet Metal
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Solution Overview
Problem
Thin sheet metal used in vehicle doors is susceptible to buckling due to the deformation caused by traditional glass-reinforced epoxy panel stiffeners, which is a concern as metal thickness reduces, necessitating a solution that enhances stiffness without deforming the metal.
Innovation Solution
A reinforcement device comprising a carrier material with a patterned deposition of matrix material, including a structural adhesive and sealant, that leaves spaces between depositions to prevent deformation, and has a coefficient of thermal expansion matching that of the sheet metal, allowing for flexible and effective reinforcement without read-through.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional glass-reinforced epoxy panel stiffeners are used to increase stiffness, then the stiffness of thin sheet metal is improved, but the sheet metal deforms (read-through)
Solution Approach 1:
The matrix material is deposited in discrete segmented patterns rather than as a continuous layer. This segmentation allows the stiffener to provide localized reinforcement while leaving gaps that prevent the concentrated stress and deformation (read-through) caused by traditional continuous stiffeners.
Solution Approach 2:
The stiffener provides localized stiffness enhancement only where needed through patterned deposition, rather than uniformly across the entire panel. This local quality approach increases stiffness at critical areas while minimizing the harmful deformation effects on the surrounding thin sheet metal.
2Weight of moving object
If the gauge of metal is reduced to decrease vehicle weight, then the overall vehicle weight is reduced, but the metal becomes highly susceptible to buckling
Solution Approach 1:
The invention creates a composite structure by depositing matrix material onto a carrier material, forming a hybrid stiffener that combines the advantages of both materials. This composite approach provides enhanced buckling resistance for thin-gauge metal panels while maintaining the weight reduction benefits of using thinner base metal.
3Object-affected harmful factors
If patterned deposition with spaces is used to prevent deformation, then read-through is avoided, but the coverage area is reduced
Solution Approach 1:
The patterned deposition applies matrix material partially rather than covering the entire carrier surface. This partial action is sufficient to provide the necessary stiffness enhancement while preventing the excessive material contact that causes read-through, achieving the right balance between reinforcement and deformation prevention.
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 solution provides added stiffness to thin gauge metal panels while avoiding deformation, ensuring effective structural reinforcement without causing read-through issues, and is suitable for direct contact with sheet metal surfaces.
Implementation Method 1
a matrix material deposited onto the carrier material in a pattern that leaves a predetermined amount of space between each deposition of matrix material
Implementation Method 2
The matrix material may include a structural adhesive material
Implementation Method 3
The matrix material may include a sealant material
Implementation Method 4
The carrier may be free of any sharp corners and includes only rounded corners
Implementation Method 5
The device may include an elastic material deposited onto the carrier material in a pattern that leaves a predetermined amount of space between each deposition of elastic material
Data Source
AI summary
A device (10) comprising a carrier material (14) and a matrix material (12) deposited onto the carrier material in a pattern that leaves a predetermined amount of space (18) between each deposition of matrix material.