Powertrain Wedge With Counterforms For Transverse Force Distribution

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Solution Overview

Problem

Thermoplastic wedges for powertrains in motor vehicles lack the mechanical strength to withstand significant transverse forces, and metal inserts integrated for reinforcement pose fixing challenges due to increased thickness, compromising weight reduction and assembly efficiency.

Innovation Solution

A lightened wedge design incorporating metal inserts with counterforms and a thermoplastic connection, reinforced with continuous fiber reinforcement, which distributes lateral forces and maintains assembly conditions similar to sheet metal parts, enhancing mechanical strength and shock resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If thermoplastic material is used for the wedge to reduce weight, then weight is reduced, but mechanical strength to withstand transverse forces deteriorates

Engineering Contradiction:

Improvewedge weightVSAvoidmechanical strength against transverse forces

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The wedge combines thermoplastic material with metal inserts and continuous fiber reinforcement to create a composite structure. The thermoplastic matrix provides lightweight properties while the metal inserts and fiber reinforcement provide the necessary mechanical strength to withstand transverse forces during side impacts.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Metal inserts are strategically positioned at specific locations within the thermoplastic wedge where transverse forces are most severe. This localized reinforcement provides strength exactly where needed without adding unnecessary weight to the entire wedge structure.

Inventive Principle:

Principle #3Local quality

2Strength

If metal inserts are integrated into the thermoplastic part for reinforcement, then mechanical strength is improved, but fixing problems arise due to increased thickness

Engineering Contradiction:

Improvemechanical strengthVSAvoidfixing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Counterforms are pre-formed on the metal inserts during the stamping or bending process, before the thermoplastic material is molded over them. This preliminary shaping ensures that the limiter can properly engage with the inserts during assembly, eliminating fixing problems that would otherwise arise from the increased thickness.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The counterforms act as intermediary elements between the metal inserts and the limiter. They provide a mechanical interface that allows the limiter to engage with the thickened insert regions, mediating the connection between components with different geometries.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the wedge is designed to withstand severe mechanical stresses, then shock resistance is improved, but weight increases

Engineering Contradiction:

Improveshock resistanceVSAvoidwedge weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The wedge is segmented into distinct functional zones: thermoplastic material for lightweight structure, metal inserts for localized strength, continuous fiber reinforcement for impact resistance, and counterforms for force distribution. This segmentation allows each material to perform its optimal function without unnecessary weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design converts the harmful concentrated forces from side impacts into beneficial distributed loads. The counterforms and continuous fiber reinforcement transform impact forces into distributed stress patterns that the composite structure can withstand without requiring additional weight.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 effectively reduces the wedge's weight while maintaining mechanical strength, allowing it to withstand severe mechanical stresses during side impacts by distributing forces through counterforms and continuous fiber reinforcement, ensuring reliable assembly and impact resistance.

Implementation Method 1

an elastic part, and a limiter provided with a fixing means with an intermediate part intended to be fixed to the powertrain

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

the thermoplastic part is overmolded on a continuous fiber reinforcement connecting the inserts together

Methodology Applied

Scientific EffectTensile strength: Tension

Data Source

PatentEP3523151B1Lightweight support for a propulsion engine capable of limiting transverse forces

Publication Date: 2021.08.11 PSA AUTOMOBILES SA

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Figure 2a~2b
Figure 3~4a

AI summary

The invention relates mainly to a shim (10) for a powertrain, in particular of a motor vehicle, comprising: - two inserts (12), each having an interface (14) for the attachment thereof to a structural element of the vehicle, - a portion made of a thermoplastic material and connecting said inserts (12) with an elastic part, and - a limiter (22) provided with a means (24) for the attachment thereof to an intermediate part (25) to be fastened to said powertrain, characterised in that at least one counterform (36) is provided on each insert (12), such that the limiter (22) bears against the counterform (36) when a transverse force is applied.