Sandwich Structural Member Attachment Feature Design
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Solution Overview
Problem
Existing sandwich-type composite structures used in vehicles face limitations in design freedom and attachment capabilities due to material thickness, with attachment features often occupying valuable space and failing to withstand large forces and torques.
Innovation Solution
A sandwich-type structural member with a core having a large number of cavities, bonded to outer layers by press molding, featuring a locally crushed depression with a connector secured to the bottom surface to attach additional members, enhancing force and torque resistance while minimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If attachment features are added to composite components, then attachment capability is improved, but valuable cargo space is occupied
Solution Approach 1:
The attachment feature is nested within the composite component structure itself. The recessed portion is formed by crushing the cellular core material, creating a cavity that houses the attachment mechanism. This nesting approach allows the attachment feature to be integrated into the existing structure without adding external protrusions that would occupy cargo space.
Solution Approach 2:
The attachment feature is created by locally crushing the cellular core material at specific locations rather than uniformly modifying the entire component. This localized modification creates recessed portions with enhanced attachment capability while preserving the original structure and cargo space in other areas of the component.
2Adaptability or versatility
If attachment features are added to composite components, then attachment capability is improved, but the ability to withstand large forces and torques deteriorates
Solution Approach 1:
The attachment feature utilizes a composite construction where the crushed cellular core material forms a recessed portion that is integrated with the outer layers of the composite component. This composite structure, combining the crushed core with the surrounding intact material, creates a robust attachment feature capable of withstanding large forces and torques while maintaining the overall structural integrity of the component.
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 provides a robust attachment feature that can withstand significant pull-out, push-in, and torque forces, improving design freedom and workability while minimizing space, thus enhancing the structural integrity and functionality of composite components in vehicles.
Implementation Method 1
The outer layers are bonded to the core by press molding
Implementation Method 2
A portion of the panel is locally crushed by the press molding to form a depression
Data Source
AI summary
A sandwich-type, generally planar, structural member having an attachment feature and an assembly utilizing same are provided. The member includes a first outer layer having an outer surface, a second outer layer and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. A portion of the member is locally crushed by the press molding to form a depression. The depression has bottom and side surfaces formed by the first outer layer. The member further includes a connector fixedly secured to the bottom surface of the depression to attach a second generally planar member to the first outer layer of the structural member.