Plastic Motor Vehicle Front Face with Inserted Metal Reinforcement
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Solution Overview
Problem
The existing methods for enhancing the mechanical strength and rigidity of a motor vehicle's technical front face structure made of plastic material are complex and costly, relying on metal-plastic hybrid injection techniques that require specialized skills and increased assembly costs.
Innovation Solution
A one-piece plastic frame with integrated metal reinforcement elements, where a metal crosspiece is housed within a longitudinal housing and secured using screws at both ends and along its length, eliminating the need for hybrid injection and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal inserts are overmolded during production of the plastic front panel to ensure rigidity, then the mechanical strength and rigidity of the chassis is improved, but the manufacturing complexity and assembly costs increase due to hybrid metal-plastic injection molding requirements
Solution Approach 1:
The reinforcement system is segmented into separate metal reinforcement elements that are inserted into pre-formed recesses in the plastic chassis, rather than being integrated through hybrid injection molding. This allows the metal and plastic components to be manufactured independently and assembled separately, reducing manufacturing complexity while maintaining structural rigidity.
Solution Approach 2:
The recesses for receiving metal reinforcement elements are pre-formed in the plastic chassis during plastic injection molding, before the metal elements are inserted. This preliminary preparation simplifies the subsequent assembly process by providing ready-made receptacles for the reinforcement elements, eliminating the need for complex hybrid injection molding operations.
2Strength
If hybrid metal-plastic injection molding is used to join metal reinforcement inserts, then the rigidity of the plastic front panel is ensured, but assembly costs increase due to specialized skills and complex processes
Solution Approach 1:
The manufacturing process is segmented into separate steps: plastic chassis production with pre-formed recesses, separate metal reinforcement element production, and final assembly through insertion and fastening. This segmentation allows each component to be manufactured using standard, cost-effective processes rather than expensive hybrid injection molding.
Solution Approach 2:
The recesses in the plastic chassis serve as intermediaries that facilitate the connection between the plastic chassis and metal reinforcement elements. These pre-formed receptacles simplify the joining process by providing ready-made interfaces, eliminating the need for complex hybrid injection molding and reducing assembly costs.
3Strength
If multiple fixing elements are used to secure the metal cross member, then the mechanical connection strength is improved, but the assembly time and complexity increase
Solution Approach 1:
The fixing system is segmented into two functional groups: primary fixing elements at the ends of the metal cross member for main structural connection, and secondary fixing elements along the length for additional stabilization. This segmentation allows assembly to proceed systematically with clearly defined steps, reducing overall assembly time while maintaining connection strength.
Solution Approach 2:
The metal cross member is first inserted into the pre-formed recesses of the plastic chassis, which preliminarily positions and stabilizes the reinforcement element. This preliminary action simplifies subsequent fastening operations by reducing misalignment and facilitating quicker installation of the fixing elements.
Data Source
Figure 1~2
Figure 3
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AI summary
The invention relates to a technical front face structure of a motor vehicle, comprising a single-component frame (1) made of a plastic material and having a front face (2), a rear face (3) and an upper edge (4), as well as a metal reinforcing element (8). According to the invention, the upper edge (4) has a housing (41) extending in a longitudinal direction of the upper edge (4), inside which a metal cross-member (81) forming the metal reinforcing element is inserted, said metal cross-member being held in position in the housing (41) by first fastening elements (83) arranged on each end of the metal cross-member and used to mechanically interconnect the metal cross-member, the frame and a bodywork structure of the vehicle when the frame is attached to the bodywork structure, and by second fastening elements (82) arranged between each of the ends of same and used to mechanically connect the metal cross-member to the frame.