Polymer Reinforcing Insert Assembly for Vehicle Front Panels
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Solution Overview
Problem
Current assembly methods for reinforcement inserts in motor vehicle technical front faces are either complex and costly due to fixing requirements, result in bulky and heavy structures, or have limited mechanical strength due to reliance on polymer material alone.
Innovation Solution
A method where a first longitudinal reinforcing insert with a curved end and a second insert form a U or Ω shape, with openings allowing a polymer material to pass through and connect them, eliminating the need for welding or screwing, and enhancing mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing inserts are fixed together by welding, screwing or riveting before covering with polymer material, then the assembly achieves sufficient mechanical strength, but the assembly process becomes complex and costly
Solution Approach 1:
The patent combines the fixing function and the covering function into a single integrated solution. The polymer material serves dual purposes: it covers the reinforcing inserts for aesthetic purposes and simultaneously acts as the fixing element that bonds the inserts together. This eliminates the need for separate welding, screwing, or riveting operations, thereby reducing assembly complexity while maintaining mechanical strength.
Solution Approach 2:
The patent replaces traditional mechanical fixing systems (welding, screwing, riveting) with a chemical bonding system using polymer material. The polymer material cures to form strong bonds between the reinforcing inserts, substituting the need for mechanical fasteners or thermal joining processes. This substitution simplifies the assembly process while providing adequate mechanical strength.
2Strength
If reinforcing inserts are fixed together by welding, screwing or riveting, then the assembly achieves sufficient mechanical strength, but assembly costs increase
Solution Approach 1:
The patent merges the covering operation with the fixing operation into a single step. The polymer material is applied to cover the reinforcing inserts and simultaneously bonds them together, eliminating the need for separate fixing operations. This reduction in the number of manufacturing steps directly lowers assembly costs while maintaining the required mechanical strength.
Solution Approach 2:
The patent replaces expensive mechanical fixing systems (welding equipment, screwing machines, riveting tools) with a simpler polymer application and curing process. This substitution eliminates the need for specialized equipment and skilled operators for complex joining operations, thereby reducing assembly costs while achieving the necessary mechanical strength.
3Ease of manufacture
If inserts are positioned without touching each other and coated with polymer material, then the assembly is simple to produce, but the mechanical strength is relatively limited
Solution Approach 1:
The patent applies local quality by concentrating the polymer material at the junctions where reinforcing inserts meet. The polymer material is specifically positioned at these critical connection points to provide maximum bonding strength where it is most needed. This localized application ensures adequate mechanical strength while maintaining the simplicity of the overall assembly process.
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
This approach results in a robust, lightweight assembly that is simpler and less expensive to produce, with the polymer material acting as a reinforcing element to connect the inserts directly, reducing assembly time and weight.
Implementation Method 1
the polymer material forms at least one element of reinforcement extending at least partially inside the passage and connecting the first reinforcement insert to the second reinforcement insert
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to right-angle assembly (10), by means of a polymer material, of a first longitudinal reinforcing insert (12) and a second longitudinal reinforcing insert (14). Each insert (12, 14) has a base wall (12a, 14a) flanked by side walls. In said assembly: - the first insert (12) comprises a curved end (16), one free end of which defines an edge (18) in planar engagement with the base wall (14a) of the second insert (14); - the curved end (16) of the first insert (12) and the second insert (14) each have, at the place where they join, an opening (20, 22) passing through the base wall (12a, 14a) thereof, said openings defining a passage passing through the inserts (12, 14) in the longitudinal direction of the first insert (12); and - the polymer material forms at least one reinforcing element extending at least partially into the passage and connecting the inserts (12, 14).