Resin Structure Uneven Thickness Impact Absorption
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Solution Overview
Problem
Existing resin structures used in vehicle components face challenges in achieving a balance between weight reduction and excellent impact absorbing properties, with complex designs and increased weight due to reinforcement methods, and difficulties in manufacturing simplicity and load distribution.
Innovation Solution
A resin structure with an uneven thickness design, featuring a thick-walled portion and two thin-walled portions, where the thickness ratios and inter-connection-point distances satisfy specific conditions, allowing for enhanced energy absorption and controlled fracture origin, manufactured using a simple press-molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ribs are disposed on the entire front surface of the structure to improve impact absorbing property, then the impact absorption capacity increases, but the weight reduction advantage of resin material cannot be sufficiently achieved and the structure becomes complicated
Solution Approach 1:
The patent applies local quality by providing ribs only in specific regions where impact loads are expected to occur, rather than uniformly across the entire front surface. This localized reinforcement strategy strengthens critical areas while maintaining weight reduction benefits in non-critical areas, resolving the contradiction between impact absorption and weight reduction.
Solution Approach 2:
The patent segments the reinforcement strategy by dividing the front surface into different regions with varying rib configurations. Some regions have ribs for impact absorption, while other regions maintain simpler structures for weight reduction. This segmentation allows the structure to achieve both improved impact absorption and weight reduction simultaneously.
2Use of energy by moving object
If the thickness of the region around the load point is increased to improve impact absorbing property, then the energy absorption capacity increases, but fracturing occurs near the boundary between thick-walled and thin-walled portions at a position different from the designed fracture origin
Solution Approach 1:
The patent applies local quality by creating an uneven thickness structure where the thickness varies specifically in the impact absorbing direction. The thick-walled portion is localized at the load point to maximize energy absorption, while the thin-walled portions are positioned elsewhere to control fracture propagation. This localized thickness variation ensures that the designed fracture origin is maintained while achieving high energy absorption.
3Weight of moving object
If a resin structure with uneven thickness is used to reduce weight, then the weight reduction is achieved, but it is difficult to simultaneously realize sufficient impact absorbing property and simple manufacturing
Solution Approach 1:
The patent applies parameter changes by systematically varying the thickness parameter in the impact absorbing direction to create an uneven thickness structure. This parameter variation is optimized to achieve the desired balance between weight reduction and impact absorption. The thickness values are carefully selected to ensure that the structure absorbs impact energy effectively while maintaining manufacturability through conventional press-molding processes.
4Strength
If the structure is reinforced to improve impact absorbing property, then the strength increases, but the manufacturing steps cannot be simplified
Solution Approach 1:
The patent merges the reinforcement features directly into the main resin structure through a single press-molding process. The ribs and uneven thickness configurations are integrated into the mold design, allowing all structural features to be formed simultaneously in one manufacturing step. This merging approach achieves improved impact absorption without adding complex manufacturing steps, as the reinforcement is built-in rather than added separately.
Data Source
AI summary
A resin structure having an impact absorbing property includes a resin member including a resin material and having an uneven thickness structure. The resin member includes a thick-walled portion having an average thickness of a first value in an impact absorbing direction and two thin-walled portions having an average thickness of less than the first value in the impact absorbing direction. The thick-walled portion is disposed between the two thin-walled portions. The Expressions (I) and (II) are satisfied.1<t1/t2<1.545×(L/d)−0.107 (I)L/d>0 (II)In Expressions (I) and (II), t1 represents an average thickness (mm) of the thick-walled portion. t2 represents an average thickness (mm) of the thin-walled portions. L represents an inter-connection-point distance (mm) between connection points formed on the two thin-walled portions, respectively, and connected to other structures. d represents a maximum height (mm) in the impact absorbing direction in a range between the connection points of the resin member.