Sand Composite Vehicle Component for Lower-Impact Manufacturing
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Solution Overview
Problem
Current motor vehicle components often utilize fossil-based materials and non-environmentally friendly production processes, leading to significant greenhouse gas emissions and unsustainable practices.
Innovation Solution
A motor vehicle component featuring a support layer with a sand composition layer, comprising virgin and recycled sand, a binder, and water, which is adhered or contiguous to the support layer, and a bio-based coating, manufactured using additive processes to reduce environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If fossil-based materials and conventional production processes are used, then manufacturing capability and structural integrity are maintained, but environmental impact and greenhouse gas emissions increase
Solution Approach 1:
The patent changes the material composition parameters by using sand (silica) as the primary component instead of fossil-based materials, and modifies the production process parameters by using additive manufacturing with digital models. This resolves the contradiction by maintaining manufacturing capability through digital fabrication while eliminating harmful fossil-based materials.
Solution Approach 2:
The patent creates a composite structure combining sand particles with binding agents to form a manufacturable material that maintains structural integrity. This composite approach allows the use of environmentally friendly sand-based materials while achieving the mechanical properties needed for vehicle components.
2Loss of substance
If recycled sand is used in the composition, then sustainability is improved, but material consistency and manufacturing precision may worsen
Solution Approach 1:
The patent specifies precise parameter ranges for the sand composition (50-95% virgin sand, 0-45% recycled sand, 2-25% binder, 0-8% water) to balance sustainability with manufacturing precision. By controlling these parameters within defined ranges, the patent achieves both recycled material usage and consistent manufacturing quality.
Solution Approach 2:
The additive manufacturing process allows for digital modeling and simulation that provides feedback on material distribution and component geometry, enabling precise control over the final product even when using recycled materials with variable properties.
3Use of energy by moving object
If additive manufacturing processes are used, then energy consumption is reduced, but manufacturing complexity may increase
Solution Approach 1:
The patent replaces conventional mechanical subtractive manufacturing processes with additive manufacturing, which builds components layer by layer using digital models. This substitution reduces energy consumption by eliminating material removal operations while the digital fabrication process manages the complexity through software control.
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 reduces the environmental footprint by utilizing recycled materials, minimizing energy consumption, and enhancing sound absorption while providing aesthetic and protective benefits, thus improving the sustainability of motor vehicles.
Implementation Method 1
enhancing sound absorption
Implementation Method 2
a layer made of a sand composition, said layer adhering and/or being contiguous to said support layer
Data Source
AI summary
A component for a motor vehicle is described provided with a support layer adapted to be fixed to a portion of the motor vehicle and a layer made of a sand composition and adhering and/or contiguous to the support layer.