Composite Stainless Door Molding Panel for Corrosion and Forming

Solution Overview

Problem

Stainless steel automotive door moldings face issues with corrosion resistance and processability due to the limitations of 300 series and 400 series stainless steels, where 300 series has excellent corrosion resistance but requires a mirror process for surface gloss and lacks magnetism, while 400 series has low tensile strength and elongation, leading to cracking during forming and bending, and poor corrosion resistance.

Innovation Solution

A bonding panel material is developed by combining a 300 series stainless steel surface material with high elongation and 400 series stainless steel base material, bonded with an adhesive layer, to enhance corrosion resistance and processability, allowing for stable forming and bending without cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If 300 series stainless steel is used for surface material, then corrosion resistance and elongation are improved, but magnetism is lost which is needed for post-processing

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmagnetism for post-processing

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The panel is divided into two distinct layers: a 300 series stainless steel surface layer for corrosion resistance and aesthetics, and a 400 series stainless steel base layer for magnetism and structural support. This segmentation allows each layer to fulfill its specific functional requirements independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates a composite panel structure by bonding 300 series and 400 series stainless steels together. This composite approach combines the advantageous properties of both material types - the corrosion resistance and surface quality of 300 series with the magnetism and formability of 400 series.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If 400 series stainless steel is used for base material, then magnetism and surface gloss are achieved, but tensile strength and elongation are insufficient causing cracks during forming

Engineering Contradiction:

Improvesurface gloss and magnetismVSAvoidtensile strength and elongation

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The panel is divided into two distinct layers: a 300 series stainless steel surface layer for corrosion resistance and aesthetics, and a 400 series stainless steel base layer for magnetism and structural support. This segmentation allows each layer to fulfill its specific functional requirements independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates a composite panel structure by bonding 300 series and 400 series stainless steels together. This composite approach combines the advantageous properties of both material types - the corrosion resistance and surface quality of 300 series with the magnetism and formability of 400 series.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If 400 series stainless steel is used, then magnetism is available for bonding and post-processing, but corrosion resistance deteriorates leading to surface discoloration

Engineering Contradiction:

Improvemagnetism for bondingVSAvoidcorrosion resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The panel is divided into two distinct layers: a 300 series stainless steel surface layer for corrosion resistance and aesthetics, and a 400 series stainless steel base layer for magnetism and structural support. This segmentation allows each layer to fulfill its specific functional requirements independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates a composite panel structure by bonding 300 series and 400 series stainless steels together. This composite approach combines the advantageous properties of both material types - the corrosion resistance and surface quality of 300 series with the magnetism and formability of 400 series.

Inventive Principle:

Principle #40Composite materials

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 bonding panel material maintains surface condition and prevents cracking during processing, offering improved corrosion resistance and processability, with reduced production costs and enhanced productivity compared to single 400 series stainless steel materials.

Implementation Method 1

an adhesive layer positioned between the surface material and the base material to bond the surface material and the base material to each other

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20260014776A1Bonding panel material for automotive door moldings and manufacturing method thereof

Publication Date: 2026.01.15 DSP CO LTD

AI summary

A bonding panel material for automotive door moldings according to the present disclosure includes a surface material made of a 300 series stainless steel panel material manufactured to a preset thickness; a base material made of a 400 series stainless steel panel material that is attached to a back surface of the surface material in a flat shape and has magnetism; and an adhesive layer positioned between the surface material and the base material to bond the surface material and the base material to each other, in which the surface material has a relatively greater elongation than the base material.