Side Sill Molding Rib Design for Injection Stress Relief
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Solution Overview
Problem
Side sill moldings in vehicles are prone to unevenness and increased material costs due to stress from injection molding and shrinkage deformation, leading to aesthetic issues and weight increments when separate brackets are used for correction.
Innovation Solution
A side sill molding design featuring a rib connecting the lower end of a clip fixing part to a gas channel part, with the rib curved at a preset angle to alleviate stress and incorporate a gas channel part formed by injecting gas, reducing material costs and weight while enhancing appearance quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate bracket is fused to the inner surface of the side sill molding to solve appearance unevenness, then the appearance quality is improved, but material costs and weight are increased
Solution Approach 1:
The patent merges the bracket function directly into the side sill molding by forming an integrated rib structure that connects the lower end of the clip fixing part to the gas channel part. This eliminates the need for separate brackets while maintaining appearance quality and structural support.
Solution Approach 2:
The rib structure serves multiple functions simultaneously: it provides structural support, maintains appearance quality by preventing unevenness, and integrates the gas channel part. This multi-functionality replaces the need for separate brackets.
2Manufacturing precision
If a separate bracket is fused to the inner surface of the side sill molding to solve appearance unevenness, then the appearance quality is improved, but the weight of the side sill molding is increased
Solution Approach 1:
The patent combines the bracket function with the main body of the side sill molding through the integrated rib structure, eliminating the need for additional separate brackets and thereby reducing overall weight.
Solution Approach 2:
The rib structure is designed as a thin, integrated feature within the molding rather than a bulky separate bracket, reducing material usage and weight while maintaining structural integrity and appearance quality.
3Ease of manufacture
If lower end ribs are positioned at the inner surface of the front plate during injection molding, then the clip fixing structure is formed, but unevenness of appearance occurs due to slide core stress and shrinkage deformation
Solution Approach 1:
The patent introduces a gas channel part with a hollow cavity that provides dimensional stability during injection molding. This three-dimensional structural element counteracts the shrinkage and stress effects that cause surface unevenness in traditional two-dimensional rib designs.
Solution Approach 2:
The gas channel part changes the physical parameters of the molding structure by introducing a hollow cavity, which alters stress distribution and shrinkage behavior during injection molding, thereby preventing appearance unevenness.
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 unevenness, reduces material costs, and enhances the rigidity and appearance quality of the side sill molding by eliminating the need for separate brackets and addressing stress-related issues through the use of a gas channel part and angled rib.
Implementation Method 1
a hollow part of the gas channel part is formed by injecting gas from one end of the side sill molding after injection-molding the side sill molding
Data Source
AI summary
A side sill molding may include a front plate configured to have a length corresponding to a length of a side sill, a top plate configured to be connected to an upper end of the front plate, a bent part configured to be connected to the top plate and have a clip part formed at an inner side thereof, and a rib configured to connect a lower end of the clip part and a preset portion of the front plate.