Reinforced Structural Element with Converging Walls for Cavity Sealing
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Solution Overview
Problem
Existing structural elements in vehicles face challenges in sealing, reinforcing, and damping cavities due to their irregular shapes and narrow sizes, which complicates moisture and contaminant prevention, reinforcement, and noise reduction.
Innovation Solution
A reinforced structural element system featuring a reinforcing element with converging walls and ribs, bonded using low-expandable adhesives, is produced via three-dimensional printing, providing enhanced mechanical properties and improved bonding surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional reinforcing elements with non-converging walls are used, then the structural element can be reinforced, but the bonding surface area is limited and connection to the structural element is insufficient
Solution Approach 1:
The reinforcing element employs converging walls that form a tapered or conical geometry rather than parallel straight walls. This curved/converging configuration increases the surface area available for bonding to the structural element while maintaining the reinforcement function. The walls converge toward one end, creating a larger bonding interface area at the wider end where connection to the structural element occurs.
2Object-affected harmful factors
If sealing elements are used to seal cavities, then moisture and contaminants are prevented from ingressing, but the cavity reinforcement and noise damping are compromised
Solution Approach 1:
The reinforcing element combines multiple functions into a single integrated component. It provides structural reinforcement to the cavity, serves as an acoustic damper to reduce noise transmission, and includes sealing capabilities to prevent moisture and contaminant ingress. This merging of sealing, reinforcement, and damping functions into one element eliminates the need for separate components and resolves the contradiction between sealing and reinforcement.
3Strength
If reinforcing elements are added to cavities, then the mechanical strength is improved, but the weight of the structural element increases
Solution Approach 1:
The reinforcing element is strategically positioned within the cavity at locations where mechanical strength is most needed, rather than uniformly distributing reinforcement throughout the entire structure. The converging wall geometry concentrates the reinforcement effect at critical stress points while minimizing overall material usage and weight. This localized approach provides maximum strength improvement for minimum weight penalty.
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 system effectively reinforces and seals structural elements, improving mechanical load-bearing capacity and noise damping while maintaining lightweight construction.
Implementation Method 1
an adhesive, wherein the adhesive bonds the reinforcing element and the structural element to one another
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a device for reinforcing a structural element in a motor vehicle, comprising a reinforcing element which has a longitudinal axis and which can be arranged in a cavity of the structural element. The reinforcing element comprises walls which extend substantially in the direction of the longitudinal axis, and the reinforcing element additionally comprises at least one open side which likewise extends in the direction of the longitudinal axis. The walls directly adjoining the open side are designed in a convergent manner in that extensions of said adjoining walls running in the direction of the open side and perpendicularly to the longitudinal axis intersect.