Vehicle Resin Part with Integral Structure Section
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Solution Overview
Problem
Existing resin parts for vehicles, such as rear fenders, face challenges in achieving high rigidity and flexibility while ensuring attachment rigidity to the vehicle body, and require design variations, which conventional fiber-reinforced resins struggle to meet effectively.
Innovation Solution
A resin part utilizing a fiber-reinforced resin with a resin structure section formed from the same material as the resin fiber, integrated onto the outer surface, which enhances bonding strength, allows for shock absorption, and provides design flexibility by protruding reinforcement sections to compensate for anisotropy and stress concentration, while using a matrix resin with a lower melting point for easier integration and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fiber-reinforced resin with carbon fiber is used, then high rigidity is obtained, but the matrix is difficult to deflect and shock absorption is limited
Solution Approach 1:
The patent changes the material parameter from conventional carbon fiber to resin fiber (such as polypropylene fiber), which fundamentally alters the mechanical properties of the matrix. This parameter change enables the matrix to be easily deflected while maintaining high rigidity through the fiber reinforcement, thus providing both rigidity and shock absorption capability simultaneously.
2Ease of manufacture
If different materials are used for resin structure section and resin part main body, then material optimization is achieved, but bonding strength is reduced
Solution Approach 1:
The patent applies homogeneity by using the same resin material for both the resin structure section and the resin part main body. This ensures that the bonding strength between these sections is maximized since they are made of identical materials that can melt into each other, while still allowing for material optimization by selecting the appropriate resin type for the specific application requirements.
3Strength
If reinforcement sections are added to compensate for anisotropy, then rigidity is improved, but the number of laminated fiber sheets increases and formability decreases
Solution Approach 1:
The patent segments the reinforcement function into two parts: the resin fiber reinforcement within the matrix for base rigidity, and the protruding resin structure sections for additional rigidity in specific directions. This segmentation allows compensation for anisotropy without increasing the number of laminated fiber sheets, as the resin structure sections are formed integrally with the main body through injection molding, maintaining good formability.
4Adaptability or versatility
If resin structure section is formed to protrude outward, then design freedom and rigidity are enhanced, but stress concentration may occur at termination points
Solution Approach 1:
The patent applies dynamics by making the protrusion height of the resin structure sections variable rather than uniform. The protrusion height gradually decreases from the vehicle body attachment section toward the end portion, creating a dynamic transition that minimizes stress concentration at termination points while maintaining design freedom and rigidity enhancement where most needed.
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 solution improves the degree of freedom in setting rigidity and flexibility, provides enhanced protective functions, and allows for novel designs with increased rigidity and reduced weight, while minimizing stress concentration and material costs.
Implementation Method 1
the matrix resin is easily melted upon joining to the resin structure section, and a strength of bonding can be increased
Data Source
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AI summary
A resin part for a vehicle includes a fender main body (41) formed of a fiber-reinforced resin (FRP) using a resin fiber, and a resin structure section (51) formed of the same resin material as the resin fiber, provided at least on an outer surface (41a) of the resin part main body (41) exposed on an outer side of a vehicle, and formed integrally with the resin part main body (41).