Single-Shot Molded Vehicle Structural Body Component
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Solution Overview
Problem
Current methods for manufacturing vehicle structural body members, such as rocker panels and spoilers, face challenges in creating one-piece structures with class A surfaces due to issues like sink marks, flow lines, and inability to handle load forces effectively, especially when made from multi-piece constructions with extruded aluminum and thin molded plastic.
Innovation Solution
A method involving injection molding with a mixture of polymer and blowing agent, where the mold is pressurized with a fluid to exert backpressure, allowing for a single shot injection and controlled cooling to form a unitary, class A surface component capable of supporting loads without additional metal or plastic supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-piece construction with extruded aluminum and thin molded plastic is used, then manufacturing ease is improved, but strength and reliability deteriorate due to inability to handle load forces
Solution Approach 1:
The patent merges multiple components (structural member and cap member) into a single integrated molded component. The one-piece construction eliminates the need for separate extruded aluminum and thin molded plastic pieces, creating a unified structure that maintains manufacturing simplicity while significantly improving strength and load-bearing capability through continuous material flow and integrated structural design.
2Strength
If one-piece structure with structural ribs or lattice work is molded, then strength is improved, but manufacturing precision deteriorates due to sink marks, flow lines and imperfections on visible surface
Solution Approach 1:
The patent applies local quality by creating different structural characteristics in different regions of the molded component. The visible surfaces are molded with smooth, defect-free finishes suitable for aesthetic requirements, while internal structural ribs and lattice work provide strength without compromising surface quality. This localized differentiation allows the component to simultaneously achieve high surface quality and enhanced structural strength.
3Loss of energy
If rocker panel depth is increased to improve aerodynamics, then drag reduction is improved, but reliability deteriorates due to increased torque and weight support requirements
Solution Approach 1:
The patent employs composite materials by integrating multiple material properties into a single molded component. The structure combines rigid structural elements with aerodynamic shaping in one piece, allowing the rocker panel to achieve both improved aerodynamics (through optimized depth and shape) and enhanced structural reliability (through integrated reinforcement ribs and lattice work that distribute loads evenly throughout 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 method produces structural body components with improved aerodynamics and load-bearing capabilities, maintaining a class A surface quality while reducing weight and costs, enabling effective support of both aerodynamic and non-aerodynamic forces.
Implementation Method 1
heating a mixture having a polymer and a blowing agent
Implementation Method 2
pressurizing a cavity of a mold with a fluid, injecting the mixture into the cavity in a single shot such that the fluid exerts backpressure against the mixture as it is injected
Implementation Method 3
cooling the mixture in the mold to form the component
Data Source
AI summary
A structural body component, such as a rocker panel or rear spoiler, and a method of manufacture. The method may include heating a mixture having a polymer and a blowing agent, pressurizing a cavity of a mold, injecting the mixture into the cavity in a single shot such while exerting backpressure against the mixture as it is injected, and cooling the mixture in the mold to form the component.