Variable Thickness Door Hinge Mount for Composite Panels
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Solution Overview
Problem
The use of composite materials for vehicle side external panels, while reducing initial die investment expenses, results in insufficient rigidity and potential damage at stress-concentrated areas like the door hinge mount, which is not comparable to steel material standards.
Innovation Solution
A door hinge mount design featuring a variable thickness structure with a mounting panel and an integrally formed edge portion, incorporating spacers and position regulating bumps, to enhance rigidity and distribute stress effectively, using a plastic composite material that mimics the rigidity of steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If composite material is used for side external panel, then initial die investment expenses are reduced, but rigidity becomes insufficient
Solution Approach 1:
The door hinge mount features a variable thickness design where the panel thickness changes in the radial direction. The thickness is greater at the center (mounting area) and gradually reduces toward the edge, creating local quality variation that optimizes both rigidity at the mounting point and overall cost-effectiveness of the composite material panel.
Solution Approach 2:
The invention uses composite materials for the side external panel to reduce initial die investment expenses compared to steel materials, while compensating for the inherent rigidity deficiency through the variable thickness design of the door hinge mount.
2Ease of manufacture
If composite material is used for side external panel, then manufacturing cost is reduced, but stress concentration area becomes damaged
Solution Approach 1:
The variable thickness design concentrates material where stress occurs (at the mounting center) and reduces it where less stress is applied (toward edges). This local quality optimization ensures damage resistance at critical areas while maintaining cost benefits of composite materials throughout the panel.
Solution Approach 2:
The invention changes the thickness parameter of the door hinge mount in the radial direction, creating a gradient structure that adapts to stress distribution patterns. This parameter variation allows the composite material to withstand stress concentration at the hinge mounting area without increasing overall panel thickness or cost.
3Ease of manufacture
If uniform thickness is used for door hinge mount, then manufacturing is simplified, but rigidity at mounting area is insufficient
Solution Approach 1:
Rather than using uniform thickness throughout, the invention applies local quality by varying the thickness specifically at the door hinge mount area. The center maintains greater thickness for mounting rigidity while edges have reduced thickness, optimizing both structural performance and manufacturing efficiency for composite panels.
Data Source
AI summary
A door hinge mount of a side external panel for a vehicle, may provide the door hinge mount, capable of being formed of a material, requiring low initial investment expenses, and securing the same level of rigidity as in the case where a steel material is used.