Plastic Composite Roof Panels with Bent Extensions for Easy Mold Removal
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Solution Overview
Problem
The challenge in manufacturing plastic composite material panels for vehicle bodies is the difficulty in removing them from molds due to bent shape portions, which complicates the assembly process and increases costs.
Innovation Solution
A manufacturing method for plastic composite material panels that includes a roof plate portion bonded to a vehicle body frame through adhesives, with roof extensions and material filling portions designed to minimize application area and improve moldability, using a gel-type plastic composite material molded by a fixed and movable die system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If plastic composite material panels are molded with bent shape portions to fit vehicle body contours, then the aesthetic appearance and aerodynamic performance are improved, but the panels cannot be smoothly taken out from the mold
Solution Approach 1:
The panel is divided into a main body portion and a bent shape portion. The bent shape portion is designed as a separate structural element that can be independently formed or attached, allowing the main body to be easily removed from the mold while the bent portion provides the desired aesthetic and aerodynamic functionality.
Solution Approach 2:
The bent shape portion is extracted as a distinct feature from the main panel structure. This extraction allows the main panel to have a simpler geometry for easy mold removal, while the bent shape portion is separately manufactured and integrated to provide the required contour fitting and aerodynamic properties.
2Weight of moving object
If the application area of plastic composite material panels is increased to cover more vehicle body surfaces, then the weight reduction and design flexibility are improved, but the assembly cost and process complexity increase
Solution Approach 1:
The vehicle body paneling system is segmented into modular plastic composite panels that can be independently manufactured and assembled. Each panel is designed with standardized connection interfaces, allowing for scalable coverage area without proportionally increasing assembly complexity. The panels can be selectively applied to different vehicle body sections based on weight reduction requirements.
Solution Approach 2:
The plastic composite material panels are designed with universal connection features and standardized dimensions that allow them to be used across different vehicle body applications. This multi-functionality enables the same panel design to be reused in various locations, reducing overall assembly complexity while maintaining weight reduction benefits across the entire vehicle body.
Data Source
AI summary
A method includes providing a gel type of plastic composite material and loading the gel type of plastic composite material on a fixed die having a first molding surface configured to mold a roof plate portion and a second molding surface configured to mold a roof extension portion. A movable die is located along a vertical direction with the fixed die. The movable die has a first molding groove configured to mold a first material filling portion, a second molding groove configured to mold a second material filling portion, and a third molding groove configured to mold a third material filling portion. The method further includes molding a plastic composite material panel.