Polymeric Engine Hood Assembly with Reinforcing Structure
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Solution Overview
Problem
Vehicle manufacturers face challenges in reducing production costs, weight, and emissions while developing engine hood assemblies that can withstand high temperatures and provide structural rigidity, as existing thermoset and fiberglass reinforced plastic materials are limited in forming operations and environmental impact.
Innovation Solution
A polymeric engine hood assembly featuring an exterior panel, fender skin, and reinforcing structure with alternating ridges and flanges forming corrugations, which are manufactured using injection molding or thermoforming, integrating thermal insulation and reducing the need for secondary operations, thereby offering structural rigidity and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset and fiberglass reinforced plastic materials are used, then structural rigidity and heat resistance are improved, but manufacturing complexity and environmental impact worsen
Solution Approach 1:
The patent uses thermoplastic composite materials that combine the structural rigidity of fiberglass reinforcement with the manufacturing advantages of thermoplastics. The composite material allows for injection molding and thermoforming processes, eliminating the need for secondary operations required by traditional thermoset materials while maintaining heat resistance and structural integrity.
Solution Approach 2:
The invention changes the material parameter from thermoset to thermoplastic, enabling different forming operations. This parameter change allows the material to be molded and formed during manufacturing without requiring post-curing or secondary operations, thereby reducing manufacturing complexity while maintaining the required strength properties through appropriate thermoplastic composite selection.
2Strength
If thermoset and fiberglass reinforced plastic materials are used, then structural rigidity is improved, but the number of production steps worsens
Solution Approach 1:
The use of thermoplastic composite materials enables integration of multiple functions into a single part through injection molding. The composite structure provides the necessary rigidity while the thermoplastic nature allows for complete forming in one operation, eliminating the multiple production steps required by traditional thermoset and fiberglass processes.
Solution Approach 2:
The invention merges the structural reinforcement function and the exterior panel function into a single integrated part. The thermoplastic composite material allows both the structural rigidity requirements and the exterior aesthetic requirements to be met in one manufacturing process, reducing the number of production steps from multiple separate operations to a single injection molding or thermoforming operation.
3Temperature
If traditional thermoset and fiberglass materials are used, then heat resistance is improved, but vehicle weight worsens
Solution Approach 1:
The invention changes from thermoset to thermoplastic materials, selecting thermoplastics with appropriate heat resistance parameters. Modern high-performance thermoplastics can withstand engine bay temperatures while being significantly lighter than traditional fiberglass reinforced thermoset materials, thus reducing vehicle weight while maintaining heat resistance.
Solution Approach 2:
The use of thermoplastic composite materials provides a favorable strength-to-weight ratio compared to traditional thermoset composites. The composite structure maintains the necessary heat resistance and structural properties while reducing density, thereby decreasing overall vehicle weight and improving fuel efficiency.
4Strength
If traditional materials and processes are used, then structural integrity is improved, but manufacturing cost worsens
Solution Approach 1:
The thermoplastic composite materials used in this invention provide structural integrity comparable to or exceeding traditional thermoset composites. The ability to form complex geometries in a single injection molding or thermoforming operation eliminates secondary operations, labor-intensive assembly steps, and associated tooling costs, thereby reducing manufacturing cost while maintaining structural integrity.
Solution Approach 2:
The invention combines multiple manufacturing functions into a single process step. The thermoplastic composite material allows for integrated forming of structural and aesthetic features in one operation, eliminating the need for separate molding, assembly, and finishing operations required by traditional materials, thus reducing manufacturing cost while preserving structural integrity.
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 polymeric engine hood assembly reduces manufacturing costs, weight, and emissions by integrating multiple functions into a single part, providing thermal insulation and structural integrity while allowing for faster fabrication and recyclability, thus addressing the limitations of traditional materials.
Implementation Method 1
applying vacuum to the space between the first polymeric sheet and the first mold half and between the second polymeric sheet and the second mold half
Implementation Method 2
applying heat to a first polymeric sheet; applying heat to a second polymeric sheet
Data Source
Figure 1
Figure 2~3
Figure 4A~4D
AI summary
A method of making a polymeric engine hood assembly for use in a vehicle can include applying heat to a first polymeric sheet, applying heat to a second polymeric sheet, stacking the first polymeric sheet and the second polymeric sheet, placing the stacked sheets between a first mold half and a second mold half, closing the first mold half and second mold half, applying vacuum to the space between the first polymeric sheet and the first mold half and between the second polymeric sheet and the second mold half, wherein the first polymeric sheet forms an exterior panel and wherein the second polymeric sheet forms a reinforcing structure; and attaching an exterior panel to a fender skin at a junction surface, wherein the reinforcing structure includes a connecting ridge extending transversely across the reinforcing structure, wherein the connecting ridge is configured to accept the junction surface of the exterior panel and the fender skin.