Vehicle Panel Sandwich Structure for Rigidity and Weight Reduction
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Solution Overview
Problem
Existing vehicle panel structures face a trade-off between achieving high panel rigidity and reducing weight, as insufficient adhesion between components can hinder the effectiveness of weight reduction strategies while compromising panel rigidity.
Innovation Solution
A vehicle panel structure comprising a sheet-like outer panel member, an inner member buried within a resin member, where the resin member is firmly attached to the inner surface of the outer panel member, enhancing panel rigidity while maintaining lightweight properties through the use of thermosetting or thermoplastic resins and strategic placement of the inner member to improve adhesion and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the outer panel is made thin to reduce vehicle weight, then weight is reduced, but panel rigidity becomes insufficient
Solution Approach 1:
The patent applies composite materials by combining a thin outer panel with a foam layer and an inner sheet to create a sandwich structure. This composite construction allows the outer panel to remain thin for weight reduction while the combined structure maintains sufficient panel rigidity through the synergistic effect of multiple materials with different properties.
Solution Approach 2:
The patent implements the nested doll principle by placing the inner sheet within the sandwich structure, nested between the outer panel and the foam layer. This nested configuration allows the inner sheet to provide reinforcement without adding significant external volume, enabling weight reduction while maintaining structural integrity.
2Strength
If a foam layer with expansion ratio of 1.03 to 1.30 times is used to reinforce the panel, then panel rigidity is improved, but adhesion to the outer panel becomes insufficient
Solution Approach 1:
The patent applies parameter changes by expanding the foam layer to a specific density range (20 to 80 kg/m³) and expansion ratio (1.03 to 1.30 times). These parameter optimizations ensure that the foam layer achieves sufficient rigidity enhancement while maintaining adequate adhesion to the outer panel, resolving the contradiction between reinforcement and bonding.
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
The proposed structure achieves excellent panel rigidity and quietness while reducing the weight of vehicle panels, effectively addressing the limitations of previous technologies by ensuring strong adhesion and improved vibration characteristics.
Implementation Method 1
a resin member 130 of which a material is a resin and which is joined to the inner surface of the outer panel member 110
Data Source
AI summary
A vehicle panel structure has: a sheet-like outer panel member; an inner member disposed to face an inner surface of the outer panel member; and a resin member of which a material is a resin and which is joined to the inner surface of the outer panel member, and at least part of the inner member is buried in the resin member.