Segmented Reinforcement Patch Minimizing Door Surface Distortion

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Solution Overview

Problem

Reinforcement patches in vehicle doors cause surface distortions due to dissimilar coefficients of thermal expansion between the patches and the door materials during the baking and curing process, leading to aesthetic issues while attempting to enhance strength and stiffness.

Innovation Solution

A reinforcement patch design featuring a substrate and a reinforcing body with angled slits and tabs that allow the patch to conform to the door during heating and cooling, allowing the substrate to flow into the slits and harden, minimizing surface distortions and providing added strength and stiffness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a reinforcement patch is attached to the vehicle door, then the strength and stiffness of the door are increased, but surface distortions occur during baking and curing

Engineering Contradiction:

Improvestrength and stiffness of the doorVSAvoidsurface distortion of the door

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The reinforcing body is divided into multiple segments separated by slits, allowing each segment to move independently during thermal expansion and contraction, preventing surface distortions while maintaining structural strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The substrate material undergoes phase change from liquid to solid during curing, and the reinforcing body is designed to accommodate thermal expansion parameters during baking, minimizing surface distortions

Inventive Principle:

Principle #35Parameter changes

2Strength

If the reinforcement patch is rigid to provide structural support, then strength is improved, but the patch cannot conform to thermal expansion of the door

Engineering Contradiction:

Improvestructural support of the doorVSAvoidconformability to thermal expansion

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The reinforcing body is segmented into multiple parts by slits, enabling each segment to expand and contract independently with thermal changes while the overall structure maintains its load-bearing capacity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reinforcing body is designed with movable tabs and slits that allow dynamic adjustment during thermal cycles, transitioning from a rigid structure to a dynamically adaptable one that conforms to door expansion while maintaining structural integrity

Inventive Principle:

Principle #15Dynamics

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 minimizes surface distortions in vehicle doors while enhancing their strength and stiffness by allowing the reinforcement patch to conform to the door's thermal expansion, resulting in a more aesthetically pleasing and structurally robust design.

Implementation Method 1

heating the vehicle body component to move first and second tabs away from each other to widen the slit between the first and second tabs

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

allowing the vehicle body component to cool, thereby moving the first and second tabs toward each other

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Implementation Method 3

hardening the substrate within the slit

Methodology Applied

Scientific EffectPhase change (hardening): Phase Change

Data Source

PatentUS11505042B2Vehicle having reinforcement patch

Publication Date: 2022.11.22 FCA US LLC

AI summary

A vehicle includes a vehicle body and a reinforcing patch. The vehicle body component defines a cavity. The reinforcing patch is disposed within and attached to the vehicle body component. The reinforcing patch includes a substrate and a reinforcing body attached to the substrate. The reinforcing body has a first tab, a second tab, and a first slit between the first and second tabs. The slit is at least partially filled by the substrate.