Resin Panel Spacer Block for Impact Energy Absorption
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Solution Overview
Problem
Resin composite vehicle panels are lightweight but brittle, leading to fractures and gaps during collisions, which inadequately protect the passenger compartment from external objects.
Innovation Solution
The introduction of a spacer block system with controlled deformation channels and tethers, made of durable resin, which absorbs impact loads and maintains panel integrity by coupling to both exterior and interior panels, providing strength, flexibility, and energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If resin composite panels are used for lightweight vehicle body construction, then vehicle weight is reduced and styling flexibility is improved, but panel strength and fracture resistance are insufficient during collisions
Solution Approach 1:
The patent applies composite materials by combining resin composite panels with metal spacer blocks to create a hybrid structure. The metal spacers provide high strength and fracture resistance while the resin panels maintain lightweight properties and styling flexibility. This composite approach resolves the contradiction by integrating materials with complementary properties into a unified panel system that achieves both weight reduction and improved strength.
Solution Approach 2:
The patent segments the panel system into distinct functional components: lightweight resin composite panels for coverage and styling, and discrete metal spacer blocks positioned at critical locations for strength reinforcement. This segmentation allows each component to optimize its specific function while working together as an integrated system, resolving the contradiction between overall weight reduction and localized strength requirements.
2Use of energy by moving object
If resin composite panels are used to reduce vehicle weight, then fuel efficiency is improved, but panel durability and protection capability are compromised during impacts
Solution Approach 1:
The patent implements beforehand cushioning by pre-positioning metal spacer blocks within the panel structure at locations anticipated to experience impact forces. These spacers act as pre-prepared reinforcement elements that absorb and distribute impact energy before it can cause panel failure, thereby maintaining protection capability while preserving the lightweight design for fuel efficiency.
Solution Approach 2:
The hybrid composite structure combines the fuel-efficient lightweight resin panels with durable metal spacers strategically placed to maintain protection capability. This allows the vehicle to achieve improved fuel efficiency through weight reduction while the metal spacers provide the necessary reliability and protection capability during impacts.
3Strength
If metal spacers are added to reinforce resin panels, then panel strength is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent applies local quality by positioning metal spacer blocks only at specific critical locations within the panel structure where strength reinforcement is most needed, rather than uniformly throughout the entire panel. This localized approach provides necessary load bearing capacity while minimizing the overall complexity and number of components that would need to be manufactured and assembled.
4Adaptability or versatility
If resin panels are designed to be lightweight and flexible, then styling versatility is improved, but gap formation and structural integrity are compromised at panel seams during collisions
Solution Approach 1:
The patent segments the panel assembly into multiple panels joined at seams, with metal spacer blocks positioned at critical seam locations. This segmentation allows each panel to maintain styling flexibility and lightweight properties, while the spacers at seam locations provide structural reinforcement to prevent gap formation and maintain integrity during collisions.
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 spacer block system enhances the resilience and durability of resin composite panels, preventing fractures and maintaining panel seam integrity during impacts by absorbing loads and allowing controlled deformation, thus improving passenger safety.
Implementation Method 1
The shaped member can be configured to absorb a substantial portion of a first load applied in a first direction
Implementation Method 2
The channel can be configured to allow a controlled deformation. The channel can allow for a controlled deformation (e.g. of the spacer and/or the spaced member)
Implementation Method 3
Tether can be configured to delay an expansion of the spacer block upon an impact
Implementation Method 4
exterior panel coupling surface can be configured to couple to an exterior panel of a vehicle
Data Source
AI summary
A spacer for vehicle panels can be shaped such that it absorbs a substantial portion of a first load, the first load applied in a first direction substantially perpendicular to the exterior panel; controllably deforms along a second direction when a second load is applied substantially along the second direction; wherein the second direction is other than the first direction. The spacer need not deform along the second direction when the first load is applied. The spacer can have a shaped member having a channel extending through the spacer perpendicular from the exterior panel, such that the spacer can controllably deform along a width of the channel.