Automobile Door Resin Panel Bulge Structure for Rigidity
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Solution Overview
Problem
Resin panels used in automobile doors lack sufficient strength and rigidity, particularly around attachment points, leading to instability when fixed to a target object due to insufficient torsional and bending rigidity.
Innovation Solution
The resin panel features a surface structure with an inner bulge, connector bulges, and an outer bulge, all made of a high-density skin layer and a low-density expanded layer, with attachment parts made of a solid layer and through holes for enhanced strength and rigidity, allowing for stable fixation to a target object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the panel body is made of expanded layer throughout to reduce weight, then weight is reduced, but strength and rigidity around attachment parts are insufficient
Solution Approach 1:
The panel body has different structural qualities in different regions: the attachment parts are made of solid layer with high strength and rigidity, while the intermediate parts are made of expanded layer with low density. This local differentiation allows the panel to be lightweight overall while maintaining sufficient strength at critical attachment locations.
2Strength
If hard layer is provided only at convex parts, then local strength is improved, but torsional and bending rigidity remain insufficient
Solution Approach 1:
Instead of only adding hard layers at surface convex parts, the invention creates a three-dimensional solid layer that extends through the thickness of the panel at attachment parts. This volumetric reinforcement provides not only local strength but also contributes to overall torsional and bending rigidity by creating a more robust structural framework.
3Reliability
If attachment parts are made of solid layer with through holes, then fixation stability is improved, but manufacturing complexity increases
Solution Approach 1:
The solid layer with through holes is formed during the injection molding process itself, rather than requiring separate post-processing steps. The mold cavity is designed to directly form the solid layer structure and through holes in the attachment parts, integrating the reinforcement feature into the base manufacturing process and avoiding additional manufacturing complexity.
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 improved strength and rigidity, especially in torsional and bending, enable the resin panel to be fixed to a target object with stability, while maintaining a lightweight design, and the solid attachment parts ensure strength even with through holes for fastening.
Implementation Method 1
the movable mold is retracted in the moving mold to increase the cavity volume in the course of solidification of the fiber-filled thermoplastic resin, thereby allowing the fiber-filled thermoplastic resin to expand
Data Source
AI summary
A plate body includes: an inner bulge protruded on one side of the panel body and recessed on the other side and has a periphery spaced from attachment parts; connector bulges having a certain width protruded on the one side of the plate body and recessed on the other side and connect the periphery of the inner bulge to the attachment parts; and an outer bulge recessed on the one side of the plate body and protruded on the other side and continuous with the inner bulge, the connector bulges and the attachment parts. The inner bulge, the connector bulges and the outer bulge of the plate body are expansion-molded and include a skin layer formed on the surface and has high resin density and an expanded layer formed therein and has a plurality of voids and low resin density relative to the skin layer.