Rocker Panel Molding With Segmented Hinges for Curved Side Profiles
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Solution Overview
Problem
The existing vehicle side structure with a rocker panel molding has limited design freedom due to a linear integral hinge along the vehicle length, restricting the shape of the outer panel to a straight line, which prohibits curved lower ends and reduces design flexibility.
Innovation Solution
The vehicle side structure incorporates a rocker panel molding with a front and rear integral hinge at different heights, allowing the outer panel to have a curved lower end and increasing design freedom, while also enhancing rigidity through the connection of foldable panels with clips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single linear integral hinge is used along the entire lower end of the outer panel, then the molding process is simplified and manufacturing is easier, but the design freedom of the rocker panel molding is restricted to linear shapes only
Solution Approach 1:
The single linear integral hinge is divided into multiple segmental integral hinges (first integral hinge and second integral hinge) arranged along the lower end of the outer panel. Each segment can be bent independently along its own straight line, allowing the lower end to form curved shapes while maintaining the simplicity of integral molding without requiring complex multi-piece assemblies.
2Adaptability or versatility
If the outer panel is designed with a curved lower end to increase design freedom, then aesthetic versatility is improved, but the molding process becomes more complex as the resin would surround mold features
Solution Approach 1:
The integral hinges are designed with reduced thickness and specific geometry in advance during the molding design stage, creating predetermined bend lines that allow the panel to be formed into curved shapes after molding. This preliminary design of the hinge structure enables post-molding deformation without requiring complex mold features or intricate molding processes.
3Ease of operation
If the integral hinge has reduced thickness to enable bending, then the foldable panel can be deformed after molding, but the structural strength at the hinge location is reduced
Solution Approach 1:
The integral hinge structure is designed with non-uniform thickness distribution: the hinge portion has reduced thickness to enable bending, while the adjacent panel regions maintain sufficient thickness for structural strength. This local variation in thickness allows the hinge to be flexible while the overall structure remains strong enough to support the rocker panel molding.
Data Source
AI summary
A rocker panel molding includes an outer panel including a front integral hinge that is bendable along a first straight line extending along a vehicle length on a lower end of a front portion of the outer panel and a rear integral hinge that is bendable along a second straight line extending along the vehicle length on a lower end of a rear portion of the outer panel, a front foldable panel configured to be folded at the front integral hinge and fixed to a rocker panel, and a rear foldable panel configured to be folded at the rear integral hinge and fixed to the rocker panel.