Separable Polymer Reinforcement Insert Assembly
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Solution Overview
Problem
Existing assemblies of reinforcement inserts in motor vehicle technical front faces face challenges in achieving a robust, lightweight, and cost-effective design that allows for easy assembly and maintenance, as current methods require specific fixing means like welding or screwing, and do not enable separation of components for maintenance.
Innovation Solution
The assembly uses polymer material-covered reinforcement inserts with interlocking ends connected by polymeric joining elements that can be cut along specific lines for separation, allowing for robust connection without additional fixing means and enabling reassembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing inserts are joined by welding, screwing, or riveting, then the mechanical strength of the assembly is improved, but the assembly process becomes more complex and costly due to additional positioning and fastening steps
Solution Approach 1:
The polymer material serves dual functions: it acts as both the structural covering/encasement of the reinforcing inserts and as the joining medium that bonds the inserts together. This merging of functions eliminates the need for separate fastening operations (welding, screwing, or riveting), thereby reducing assembly complexity while maintaining mechanical strength through the polymer's bonding and structural properties
2Strength
If reinforcing inserts are joined by embedding with T-shaped overlap zone, then the mechanical strength and robustness of the assembly is improved, but the assembly becomes bulky and heavy, and the embedded elements cannot be separated for maintenance
Solution Approach 1:
The polymer material containing joining elements is divided into distinct functional zones: covering portions that encase the reinforcing inserts and joining elements that bond the inserts together. This segmentation allows the polymer to provide both structural support and bonding functions without requiring excessive material volume, thereby reducing the bulk and weight compared to traditional embedded T-shaped overlap zones while maintaining assembly robustness
3Ease of manufacture
If reinforcing inserts are positioned without touching and encased in polymer material, then the assembly is simplified, but the mechanical strength depends solely on the polymer material bonding which is relatively limited, and the inserts cannot be separated for maintenance
Solution Approach 1:
Joining elements are introduced as intermediary components within the polymer material that actively mediate the bonding between reinforcing inserts. These joining elements provide enhanced bonding mechanisms beyond the base polymer material, creating stronger connections between inserts while maintaining the simplified encasement manufacturing process. The joining elements act as mediators that transfer and distribute loads more effectively through the polymer matrix
4Strength
If reinforcing inserts are joined by polymer material without separable features, then the assembly is robust and simple, but the reinforcing inserts cannot be separated for maintenance
Solution Approach 1:
The joining elements are designed with dynamic characteristics that allow them to be cut or separated along predetermined lines when maintenance is required. This dynamic design enables the assembly to transition from a permanently bonded state to a separable state, allowing reinforcing inserts to be removed for maintenance while maintaining strong connection during normal operation. The joining elements incorporate cut lines that facilitate clean separation without compromising the overall structural integrity of the remaining assembly
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
This solution provides a lightweight, cost-effective assembly that can be easily separated and reassembled, facilitating maintenance while maintaining mechanical strength, and allows for the integration of external structures through orifices.
Implementation Method 1
said ends of the first and second reinforcing inserts are joined by at least two polymer material connecting external surfaces of the first reinforcing insert to external surfaces of the second reinforcing insert
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to an assembly (10) of a first longitudinal reinforcement insert (12) and a second longitudinal reinforcement insert (14) by a polymer material (20) at least partially covering the same, each reinforcement insert (12, 14) having an open concave transverse cross-section, the longitudinal directions of said reinforcement inserts (12, 14) being substantially perpendicular and the reinforcement inserts being orientated such that the concavity thereof is directed in the same direction. One end of the second reinforcement insert (14) is fitted to one end of the first reinforcement insert (12). The ends of the first and second reinforcement inserts are rigidly attached by at least two joining elements (22, 24) made of polymer material, said joining elements (22, 24) being arranged to allow a separation of the first and second inserts after cutting said junction elements along at least one cutting line (26, 27).