Vehicle Panel Assembly With Perimeter Core for Frame-Free Mounting

Solution Overview

Problem

Existing vehicle panel assemblies are complex, heavy, and costly to manufacture, with a metal frame adding significant weight and complexity, which negatively impacts fuel efficiency and installation ease.

Innovation Solution

A panel assembly comprising a first and second face sheet with a core layer defined by a base material along one section and a honeycomb structure along another section, eliminating the need for a discrete metal frame and allowing for tool-less mounting using fasteners that extend through holes in the face sheets and base material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a metal frame is used to hold the composite panel, then the panel assembly achieves structural stability and mounting capability, but the weight of the panel assembly increases significantly

Engineering Contradiction:

Improvepanel assembly weightVSAvoidstructural stability

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent removes the metal frame component entirely from the panel assembly. The composite panel itself is designed with integrated mounting features (flanges or tabs extending from the panel edges) that directly attach to the bulkhead, eliminating the need for a separate metal frame structure while maintaining mounting capability and structural stability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the panel holding function and mounting function into the composite panel itself. The panel includes integrated mounting features that perform both the structural support role previously assigned to the metal frame and the panel retention role, merging multiple functions into a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If a metal frame is used to hold the composite panel, then the panel assembly achieves mounting capability, but the device complexity increases

Engineering Contradiction:

Improveinstallation easeVSAvoidpanel assembly complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent removes the metal frame component entirely from the panel assembly. The composite panel itself is designed with integrated mounting features (flanges or tabs extending from the panel edges) that directly attach to the bulkhead, eliminating the need for a separate metal frame structure while maintaining mounting capability and structural stability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the panel holding function and mounting function into the composite panel itself. The panel includes integrated mounting features that perform both the structural support role previously assigned to the metal frame and the panel retention role, merging multiple functions into a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If a metal frame is used to hold the composite panel, then the panel assembly achieves structural support, but the manufacturing cost increases

Engineering Contradiction:

Improvemanufacturing economyVSAvoidstructural support capability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent removes the metal frame component entirely from the panel assembly. The composite panel itself is designed with integrated mounting features (flanges or tabs extending from the panel edges) that directly attach to the bulkhead, eliminating the need for a separate metal frame structure while maintaining mounting capability and structural stability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the panel holding function and mounting function into the composite panel itself. The panel includes integrated mounting features that perform both the structural support role previously assigned to the metal frame and the panel retention role, merging multiple functions into a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12060145B2Vehicle panel assembly and method of panel assembly

Publication Date: 2024.08.13 THE BOEING CO

AI summary

A panel assembly for use in a vehicle includes a first face sheet, a second face sheet, and a core layer disposed between the first and second face sheets. The core layer is defined by a base material along a first section of the panel assembly, and the core layer is defined by a honeycomb structure along a second section of the panel assembly. The first section and the second section are discrete, and the first section that includes the base material extends along a perimeter of the panel assembly.