Resin Reinforcing Material for Outer Panel Strain Prevention
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Solution Overview
Problem
Conventional steel plate-reinforcing materials cause strain on vehicle design surfaces when used with thinner steel or aluminum panels, leading to design surface deformations, and modifying the shape of the reinforcing material is cumbersome and ineffective in preventing strain.
Innovation Solution
A reinforcing material with a resin layer containing low-polarity rubber, acrylonitrile-butadiene rubber, flexible epoxy resin, and a thermally-degradable foaming agent, which is adhered to the outer panel and heated to provide a 1 mm displacement strength of 20 N or more and a strain amount of 170 µm or less, preventing surface strain without shape modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional steel plate-reinforcing materials are used with thinner steel or aluminum panels, then the panels can be made lighter, but the design surfaces become strained and deformed
Solution Approach 1:
The invention changes the chemical composition parameters of the resin layer by incorporating specific rubber components (low-polarity rubber and acrylonitrile-butadiene rubber) in controlled ratios. This compositional parameter change enables the resin to accommodate panel thickness variations and material differences (steel vs. aluminum) while maintaining adequate adhesion and preventing surface strain, thus allowing lighter panels without compromising design surface integrity
Solution Approach 2:
The invention creates a composite resin layer combining multiple rubber components (low-polarity rubber and acrylonitrile-butadiene rubber) with epoxy resin and curing agents. This composite material structure provides both flexibility to prevent surface strain and sufficient adhesion strength to reinforce the panel, resolving the contradiction between panel lightness and surface integrity
2Shape
If the shape of the reinforcing material is modified to prevent strain, then surface integrity can be maintained, but the production process becomes more complex and time-consuming
Solution Approach 1:
Instead of modifying the geometric shape of the reinforcing material, the invention changes the chemical and physical parameters of the resin layer composition. By adjusting the rubber component ratios and types, the material gains inherent flexibility and strain-absorption capabilities, allowing it to maintain design surface integrity while keeping the production process simple and straightforward
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 solution effectively reinforces vehicle outer panels by preventing strain on the design surface without altering the reinforcing material's shape, ensuring both strength and surface integrity.
Implementation Method 1
the foaming agent is preferably a thermally-degradable foaming agent
Implementation Method 2
a sheet-like resin layer formed of a thermosetting resin composition
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
The present invention relates to a reinforcing material for outer panel, which is adhered to an outer panel for reinforcing the outer panel, in which the reinforcing material has: a 1 mm displacement strength of 20 N or more when adhered to an entire surface of a cold-rolled steel plate having a size of 25 mm width × 150 mm length × 0.8 mm thickness and then heated at 180°C for 20 minutes; and a strain amount of 170 µm or less when adhered to a center part of an aluminum panel having a size of 200 mm width × 300 mm length × 1 mm thickness, in the form of a rectangular having a size of 50 mm width × 100 mm length, and then heated at 180°C for 20 minutes.