Vehicle Front Reinforcement Inserts Assembly

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Solution Overview

Problem

Existing assembly methods for reinforcing inserts in motor vehicle technical front faces are either bulky and heavy, or lack sufficient mechanical strength, due to complications in fixing operations and reliance on polymer material alone for connection.

Innovation Solution

The use of reinforcing inserts with concave open cross-sections, such as U or Ω shapes, where one insert's edge bears against the other, secured by a fixing lug with aligned orifices, and covered partially with polymer material, allowing direct contact and reinforcement via polymer material and subsequent attachment to structural elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding, screwing or riveting is used to assemble reinforcing inserts, then the mechanical strength of the assembly is improved, but the positioning and fixing operations complicate the assembly process and increase assembly costs

Engineering Contradiction:

Improvemechanical strength of assemblyVSAvoidcomplexity of positioning and fixing operations

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical assembly methods (welding, screwing, riveting) with a polymer material bonding system. The polymer material is injected into the mold cavity where it bonds the reinforcing inserts together, eliminating the need for complex positioning and fixing operations while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the bonding mechanism from mechanical (screws, welds) to chemical/adhesive (polymer material bonding). The polymer material undergoes curing or hardening to create strong bonds between inserts, transforming the assembly process into a simpler injection and curing operation.

Inventive Principle:

Principle #35Parameter changes

2Strength

If T-shaped zones are created for covering and embedding inserts before polymer coating, then a robust assembly is obtained without welding, screwing or riveting, but the assembly becomes bulky and heavy

Engineering Contradiction:

Improverobustness of assemblyVSAvoidweight of assembly

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The patent applies polymer material only where needed - specifically in the regions required to bond the reinforcing inserts together - rather than creating extensive T-shaped zones throughout the entire structure. This partial application achieves the necessary bonding strength without adding excessive bulk and weight.

Inventive Principle:

Principle #16Partial or excessive action

3Ease of manufacture

If inserts are positioned to not touch each other and coated with polymer materials, then the assembly can be produced simply, but the mechanical strength results solely from polymer material connection and is relatively limited

Engineering Contradiction:

Improvesimplicity of productionVSAvoidmechanical strength of connection

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent performs preliminary positioning of the reinforcing inserts within the mold cavity before polymer injection. The inserts are pre-aligned and secured in their final positions, ensuring direct contact and proper orientation. This preliminary action allows the polymer material to bond the inserts directly together, significantly enhancing the mechanical strength of the connection.

Inventive Principle:

Principle #10Preliminary action

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 results in a robust, light, and compact assembly that simplifies production and assembly processes, enhancing mechanical strength and reducing assembly costs while maintaining compactness.

Implementation Method 1

an assembly of a first longitudinal reinforcing insert and a second longitudinal reinforcing insert by a polymer material covering them at least partially

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentEP3186132B1Assembly of reinforcement inserts by means of a polymer material, in particular for a technical front face of a vehicle, said assembly being reinforced by the attachment of same to a structural element

Publication Date: 2018.10.03 RENAULT SA

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Figure 4~5

AI summary

The invention concerns a right-angled assembly (10) of longitudinal reinforcement inserts (12, 14), each insert (10, 12) having a concave open cross-section. According to the invention : - an edge (16) of an end of the first insert (12) bears against a convex side of the second insert (14), along a part (18a-c) of an edge of an opening (18) passing through said second insert (14), said opening (18) having an identical shape and dimensions to those of the cross-section of the end of the first insert (12), - a polymer material at least partially covers said inserts (12, 14) at least at the junction of same, - a mounting bracket (20) rigidly connected to the second insert and adjacent to the opening (18) bears against an end wall (13) of the first insert (12), said wall (13) and said mounting bracket (20) being pierced with holes (13a, 13b; 20a, 20b) facing each other.