Polymeric Carrier With Localized Fibrous Insert
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Solution Overview
Problem
There is a need for alternative structural reinforcement carrier structures in the automotive industry that combine dissimilar materials compatible for joining without adhesives, provide weight savings, increase modulus and flexural strength, and offer localized reinforcement without additional structural features like ribs, while maintaining a continuous interface and smooth surfaces.
Innovation Solution
A structural reinforcement system comprising a polymeric carrier with consolidated fibrous inserts having ordered fibers, which are compatible with the polymeric material, allowing for partial joining and saturation with a thermoplastic epoxy resin, and an activatable material that expands and bonds to surfaces for enhanced rigidity and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If dissimilar materials are combined for reinforcement, then weight savings and strength improvement are achieved, but compatibility for joining without adhesives becomes difficult
Solution Approach 1:
The patent changes the chemical parameters of the polymeric materials to achieve compatibility. Specifically, it uses polymeric materials with complementary chemical groups (such as epoxy groups and amine groups) that can chemically bond to each other, enabling dissimilar materials to join without adhesives while maintaining both strength improvement and manufacturing ease
Solution Approach 2:
The patent employs composite material structures where dissimilar polymeric materials are combined in a carrier system. The composite structure allows each material to contribute its unique properties (weight savings, strength) while the chemical compatibility between materials enables direct joining, resolving the contradiction between material diversity and joining ease
2Strength
If localized reinforcement is added, then strength at specific locations is improved, but additional structural features like ribs increase complexity
Solution Approach 1:
The patent applies local quality by incorporating fibrous inserts at specific localized regions within the carrier where reinforcement is needed. These fibrous inserts provide targeted strength enhancement at predetermined locations without requiring additional structural features like ribs, thereby improving localized strength while maintaining simplicity
Solution Approach 2:
The patent segments the reinforcement function by separating the carrier structure from the reinforcement function. The fibrous inserts are distinct segments that can be independently placed and configured at specific locations, allowing localized reinforcement without complicating the overall structural design
3Weight of moving object
If multiple materials are used for reinforcement, then weight savings are achieved, but maintaining a continuous interface without visible knit lines becomes difficult
Solution Approach 1:
The patent changes the physical and chemical parameters of the polymeric materials to ensure compatible melting and bonding behaviors. By selecting materials with similar processing temperatures and compatible chemical structures, the patent achieves seamless interfacing of multiple materials without visible knit lines, maintaining both weight savings and manufacturing precision
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 a unitary, continuous carrier structure with improved strength and sealing capabilities, allowing for customized localized reinforcement and weight savings, with no visible knit lines or voids, and can be applied in transportation vehicles for structural reinforcement and noise abatement.
Implementation Method 1
a carrier, which includes a mass of polymeric material and at least one consolidated fibrous insert... The fibrous insert and the mass of polymeric material include materials, structures or both, that are compatible for joining the fibrous insert to the mass of polymeric material
Implementation Method 2
For certain activatable materials, upon being activated (e.g., by the heat from a coating bake oven), the activatable material can expand and bond to a surface defining the cavity
Data Source
AI summary
A structural reinforcement for an article including a carrier that includes: (i) a mass of polymeric material having an outer surface; and (ii) at least one consolidated fibrous insert (14) having an outer surface and including at least one elongated fiber arrangement having a plurality of ordered fibers arranged in a predetermined manner. The fibrous insert is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert and the mass of polymeric material are of compatible materials, structures or both, for allowing the fibrous insert to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier may be a mass of activatable material.