Board-Type Sunshade Composite Core for Higher Rigidity at Lower Weight
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Solution Overview
Problem
Conventional board-type sunshades for motor vehicles face a trade-off between rigidity and weight, where increasing the basis weight of resin-impregnated glass fiber mats for higher rigidity results in increased weight, limiting the use of thermosetting resin and failing to meet demands for further improvement in rigidity and strength.
Innovation Solution
A board-type sunshade configuration featuring a core member with two glass fiber mats and a resin-impregnated semi-hard urethane foam layer, where the semi-hard urethane foam layer is impregnated with a liquid thermosetting resin to enhance rigidity, allowing for a higher basis weight of thermosetting resin without significantly increasing the weight of the sunshade.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the basis weight of resin-impregnated glass fiber mats is increased to improve rigidity, then the rigidity of the sunshade is improved, but the weight of the sunshade increases
Solution Approach 1:
The patent uses a composite core member structure combining glass fiber mats with semi-hard urethane foam layer. The glass fiber mats provide rigidity while the foam provides lightweight properties and flexibility. This composite approach allows achieving the required rigidity without using excessive amounts of heavy glass fiber material alone.
Solution Approach 2:
The patent changes the physical state and distribution of thermosetting resin by impregnating it into the semi-hard urethane foam layer. This allows the resin to be distributed throughout the foam structure, creating rigid sections where needed while maintaining the overall lightweight foam architecture, rather than using solid glass fiber mats throughout.
2Strength
If the basis weight of thermosetting resin impregnated into glass fiber mat is increased to enhance rigidity, then the rigidity of the sunshade is improved, but the weight of the sunshade increases
Solution Approach 1:
The patent utilizes the porous structure of semi-hard urethane foam as a medium for thermosetting resin impregnation. The foam's cellular structure allows resin to penetrate and distribute throughout the volume, creating rigid reinforced sections within the lightweight foam matrix. This porous material approach enables high resin basis weight without proportionally increasing overall weight.
Solution Approach 2:
The patent creates a composite structure where thermosetting resin-impregnated foam combines the lightweight properties of foam with the rigidity of cured resin. This composite material achieves higher rigidity than solid glass fiber mats at lower weight by utilizing the foam's volume and the resin's structural properties.
3Strength
If two glass fiber mats are used to ensure rigidity, then the rigidity of the sunshade is improved, but the weight of the sunshade increases
Solution Approach 1:
The patent replaces the conventional two-layer glass fiber mat structure with a composite core member consisting of glass fiber mats combined with semi-hard urethane foam. The foam fills the space between and around the glass fiber mats, providing structural support and rigidity distribution throughout the entire volume, reducing the need for multiple heavy glass fiber layers.
Solution Approach 2:
The patent transitions from a two-dimensional layering approach (multiple glass fiber mats stacked) to a three-dimensional composite structure where foam infiltrates throughout the volume between glass fiber mats. This dimensional approach distributes rigidity throughout the entire core member volume rather than concentrating it in discrete layers.
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 configuration significantly improves the rigidity of the sunshade, enabling it to maintain its board shape without deformation under external forces while minimizing weight increase, thus addressing the limitations of conventional designs.
Implementation Method 1
the semi-hard urethane foam layer is impregnated with a liquid thermosetting resin
Implementation Method 2
curing the liquid thermosetting resin
Data Source
AI summary
A sunshade is formed by laminating a front skin member, a core member, and a back skin member in this order, and the core member is formed by laminating a resin-impregnated semi-hard urethane foam layer between two glass fiber mats.