Polymer Assembly of Reinforcement Inserts Without Welding
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Solution Overview
Problem
Existing methods for assembling reinforcement inserts in motor vehicle technical front faces are cumbersome and costly due to the need for welding, screwing, or riveting, and alternative solutions result in either bulky or mechanically weak assemblies.
Innovation Solution
A robust assembly of reinforcement inserts using a polymer material that covers the inserts at least partially, with retaining lugs on one insert cooperating with the other to prevent movement, eliminating the need for specific fastening means and allowing the polymer material to hold the inserts in place during overmolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding, screwing or riveting is used to assemble reinforcement inserts, then the connection strength is improved, but the assembly process becomes more complex and costly
Solution Approach 1:
The patent merges the fastening function with the polymer material itself. The retaining lugs are integrated into the insert structure, and the polymer material serves both as structural component and as the medium that provides the connection strength, eliminating the need for separate fastening operations
Solution Approach 2:
The retaining lugs are designed to automatically engage with the polymer material during the injection molding process. The polymer material itself performs the fastening function by filling the recesses and mechanically interlocking with the lugs, making the assembly process self-service without requiring additional welding, screwing, or riveting steps
2Strength
If overlapping and embedding zones are created for inserts, then the assembly robustness is improved, but the assembly becomes bulky and heavy
Solution Approach 1:
Instead of creating extensive overlapping zones throughout the insert structure, the patent applies local quality by concentrating the reinforcement only where needed - at the ends of inserts where retaining lugs are positioned. The polymer material is injected specifically into recesses at these critical locations, providing localized robustness without adding bulk to the entire assembly
Solution Approach 2:
The insert structure is segmented into distinct functional zones: the main body of the insert and the end portions with retaining lugs. This segmentation allows the polymer material to be strategically placed only at the connection points rather than throughout the entire overlap zone, reducing unnecessary material and weight while maintaining assembly robustness
3Ease of manufacture
If inserts are positioned without touching each other and coated with polymer material, then the manufacturing simplicity is improved, but the mechanical strength becomes limited
Solution Approach 1:
The retainin lugs are pre-formed on the insert ends before the polymer injection process. This preliminary action creates ready-to-engauge features that guide the polymer material flow and ensure proper positioning during injection, maintaining manufacturing simplicity while enabling strong mechanical interlocking
Solution Approach 2:
The polymer material acts as an intermediary between the non-touching insert ends. Rather than relying on direct contact between inserts, the injected polymer fills the gap and creates a positive mechanical interlock with the retaining lugs, transforming the weak polymer-only connection into a strong composite joint
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 method provides a lightweight, robust connection between reinforcement inserts without increasing assembly weight, simplifying the assembly process, and reducing costs by eliminating the need for additional fastening methods.
Implementation Method 1
a robust assembly of reinforcement inserts by a polymer material, without welding or screwing of the latter... in that said polymeric material covers said reinforcing inserts at least at their facing ends
Data Source
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AI summary
The invention relates to an assembly (10) of two longitudinal reinforcement inserts (12, 14) by a polymer material at least partially covering same, each reinforcement insert (12, 14) having a bottom wall (12a, 14a) and two side walls (12b, 12c; 14b, 14c) connected such that a reinforcement insert (12, 14) has a concave open cross-section, in particularly substantially U or Ω shaped, the longitudinal directions of said reinforcement inserts (12, 14) being substantially perpendicular. According to the invention, one end of a first reinforcement insert (12) has at least two supporting tabs (16, 18) engaging with one end of the second reinforcement insert (14) in order to block any movement of the latter in the longitudinal direction of the first reinforcement insert (12) and the polymer material covers said reinforcement inserts (12, 14) at least at the ends thereof in contact.