Patterned Two-Sheet Shear Panel for Strength and Drainage
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Solution Overview
Problem
Existing vehicle components face challenges in achieving a balance between structural strength, energy absorption, and weight reduction, particularly in the context of automotive applications where both adequate strength during normal service and energy absorption under extraordinary conditions are required.
Innovation Solution
A patterned two-sheet shear panel construction comprising a patterned upper and lower sheet metal panel with protruding strengthening crossbar sections, secured by welds or adhesives, made from materials like steel, aluminum, or composites, which eliminates the need for separate stringer components and facilitates liquid drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If vehicle structural assemblies use heavier materials or thicker panels to improve strength, then strength and energy absorption improve, but weight increases reducing efficiency
Solution Approach 1:
The panel is segmented into a two-sheet construction with upper and lower sheets separated by strengthening crossbars. This segmentation creates a space-efficient structure that provides high strength-to-weight ratio by distributing loads across multiple elements rather than using a single heavy panel.
Solution Approach 2:
The invention uses composite construction combining two separate sheet metal panels with strengthening crossbars between them. This composite structure achieves superior strength and energy absorption characteristics compared to single-sheet designs while maintaining lightweight properties through optimized material distribution.
2Strength
If separate stringer components are added to improve structural performance, then strength improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The strengthening crossbars serve dual functions as both structural strengtheners and integrated stringer components. By merging these functions into a single integrated element rather than using separate components, the design reduces assembly complexity while maintaining structural performance.
Solution Approach 2:
The strengthening crossbars are designed to perform multiple functions simultaneously: providing structural strengthening, acting as stringers for mounting components, and serving as attachment points for the two-sheet construction. This multi-functionality eliminates the need for separate dedicated stringer components.
3Strength
If panel design prioritizes strength through solid construction, then structural support improves, but drainage capability deteriorates
Solution Approach 1:
The lower sheet is designed with localized drainage holes at specific positions to enable water drainage while maintaining overall structural integrity. This local modification allows the panel to simultaneously provide strong structural support through the two-sheet construction while eliminating water accumulation issues through targeted drainage features.
Data Source
AI summary
A shear panel construction includes a patterned upper sheet metal panel including a planar section and having a plurality of upwardly protruding portions defining first strengthening crossbar sections extending upward from the planar section, the planar section of the patterned upper sheet metal panel extends to an edge of the patterned upper sheet metal panel. A patterned lower sheet metal panel is secured to a bottom surface of the patterned upper sheet metal panel, the patterned lower sheet metal panel having a plurality of protruding portions defining second strengthening crossbar sections.