Moulded Underbody Panel Mounting Point Blocking Element
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Solution Overview
Problem
Moulded underbody panels for vehicles face issues with mounting point failure due to localized stress and material rupture under heavy loads, particularly during water wading or high-speed driving, as the existing mounting systems are prone to loosening and material thinning, leading to potential rupture of through-holes.
Innovation Solution
Incorporating a raised blocking element around the through-hole, formed as a ridge or embossing, which increases the contact area and distributes the force over a larger surface, preventing the rod-shaped element from directly contacting the panel material and reducing the risk of material failure, thereby enhancing the pull-out strength of the mounting points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a through-hole is used for mounting the panel, then the panel can be fixed to the vehicle chassis, but the mounting point becomes prone to material thinning and rupture under heavy loads
Solution Approach 1:
The patent applies local quality by creating a blocking element with different properties than the surrounding panel material. The blocking element has higher density and strength, concentrated specifically at the mounting point area to reinforce the through-hole region without adding weight to the entire panel. This localized reinforcement prevents material thinning and rupture at the critical mounting area.
Solution Approach 2:
The patent uses composite materials by combining the base panel material with a blocking element made of different material properties. The blocking element can be formed from the same thermoplastic material but with different processing conditions creating varying density, or from a different material entirely, creating a composite structure that leverages the strengths of each material at the mounting point.
2Strength
If the contact area around the through-hole is increased to distribute force, then the mounting strength improves, but the panel weight increases
Solution Approach 1:
The blocking element concentrates the reinforcement function in a localized area around the through-hole, increasing contact area and force distribution capability only where needed for mounting strength, while leaving the rest of the panel lightweight. The blocking element's compact geometry ensures minimal weight addition.
Solution Approach 2:
The blocking element extends in the thickness dimension of the panel, creating a three-dimensional reinforcement structure around the through-hole. This vertical dimension provides additional surface area for force distribution and mechanical interlocking with the fixing element, achieving enhanced mounting strength without increasing the panel's planar footprint.
3Strength
If a blocking element is added to prevent material failure, then the pull-out strength increases, but the manufacturing complexity increases
Solution Approach 1:
The blocking element is merged with the panel as an integral feature, formed during the same molding process. This integration eliminates the need for separate assembly steps and reduces the number of discrete parts. The blocking element becomes an inherent part of the panel structure, simplifying the overall mounting system while maintaining enhanced pull-out strength.
Solution Approach 2:
The blocking element is formed preliminarily during the panel molding process, before the mounting operation. This preliminary formation of the reinforcement structure eliminates the need for subsequent assembly steps or additional processing, reducing manufacturing complexity while ensuring the mounting point is pre-reinforced for high pull-out strength.
4Ease of manufacture
If the blocking element is formed integrally with the panel, then the manufacturing process is simplified, but the molding process complexity increases
Solution Approach 1:
The molding process is segmented into distinct phases: forming the main panel body, then forming the blocking element as a separate feature within the same mold. This segmentation allows each feature to be optimized independently while maintaining integral construction, balancing manufacturing simplicity with molding process capabilities.
Solution Approach 2:
The molding tool is designed with multi-functionality to perform both panel formation and blocking element creation in a single operation. The mold incorporates features that can form different geometries and material densities, making the same molding process capable of producing complex integral structures without requiring multiple specialized tools or assembly steps.
Data Source
Figure 1~2
Figure 3A~4B
Figure 5~6V
AI summary
Moulded underbody panel for shielding the underside of a motor vehicle, comprising a consolidated fibrous layer comprising at least one mounting point for mounting the moulded underbody panel to the vehicle by means for mounting, the means for mounting comprising at least a rod shape element, and a fixing element, whereby the mounting point consists at least of a through-hole extending through the moulded underbody panel for hosting the rod shape element, and a contact area on the moulded underbody panel surface, provided around the through-hole, for contacting and supporting the fixing element in the mounting position, wherein the mounting point further comprises a blocking element which is formed integrally with the moulded underbody panel, whereby the blocking element is raised above at least the plane of the contact area and formed around the through-hole and whereby the distance between the foot of the blocking element facing the through hole and the centre of through-hole is 5 to 20 mm.