Integrally Bonded Air-Guiding Device in Composite Vehicle Parts
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Solution Overview
Problem
The existing methods for attaching air-guiding devices to composite parts, such as those made from lightweight reinforced thermoplastics, require additional installation steps and materials like screws or rivets, increasing manufacturing costs and weight due to the need for reinforced configurations for mechanical stability.
Innovation Solution
A method that integrates the production and deformation of composite parts with the connection of air-guiding devices through a tool device, where both the composite part and air-guiding device are heated to a melting point, allowing for an integrally bonded connection without additional fastening means, reducing production costs and weight while maintaining mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connection or rivet connection is used to fasten air-guiding devices to composite parts, then mechanical stability is achieved, but manufacturing complexity and production costs increase due to additional installation steps and fastening materials
Solution Approach 1:
The patent combines the joining operation with the forming operation into a single integrated process. The air-guiding device is positioned in the tool, and during the composite part forming process, the material is simultaneously pressed and bonded to the air-guiding device, eliminating the need for separate fastening steps and reducing manufacturing complexity while maintaining mechanical stability
Solution Approach 2:
The air-guiding device is pre-positioned in the tool before the composite part forming process begins. This preliminary positioning allows the subsequent forming operation to directly create the bonded connection without requiring additional assembly steps, thereby reducing manufacturing complexity while ensuring proper mechanical alignment and stability
2Strength
If screw connection or rivet connection is used to fasten air-guiding devices to composite parts, then mechanical stability is achieved, but weight increases due to additional fastening materials and reinforced configurations
Solution Approach 1:
The patent merges the joining function with the forming function, creating a direct bonded connection between the composite part and the air-guiding device through the forming process itself. This eliminates the need for separate fastening materials like screws or rivets and removes the requirement for reinforced configurations, thereby reducing weight while maintaining mechanical stability
Solution Approach 2:
The patent extracts and eliminates the fastening materials (screws, rivets) and reinforced configuration requirements from the assembly process. By using the forming process to directly create the bonded connection, the solution removes these additional weight-contributing elements while still achieving the necessary mechanical stability
3Strength
If additional fastening materials and reinforced configurations are used, then mechanical stability is ensured, but manufacturing costs increase due to extra materials and installation steps
Solution Approach 1:
The patent combines two separate manufacturing operations (forming the composite part and joining the air-guiding device) into a single integrated process. This eliminates the need for additional fastening materials and separate installation steps, reducing material costs and labor costs while ensuring mechanical stability through the bonded connection created during forming
Solution Approach 2:
The patent extracts and eliminates the additional fastening materials (screws, rivets) and reinforced configuration requirements from the manufacturing process. By using the forming process to directly create the bonded connection, the solution removes these extra materials and installation steps, thereby reducing manufacturing costs while maintaining mechanical stability
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
This method eliminates the need for extra installation steps and fastening materials, reducing production costs and weight while maintaining or improving mechanical stability, allowing for a lightweight multi-component part with enhanced aerodynamic performance.
Implementation Method 1
heating a composite part having at least one mating contact portion for a pressing operation to a melting point of at least one material component of the composite part
Implementation Method 2
heating a composite part having at least one mating contact portion for a pressing operation to a melting point of at least one material component of the composite part
Implementation Method 3
heating the at least one contact portion of the at least one air-guiding device to a melting point of at least one material component of the contact portion of the air-guiding device
Implementation Method 4
heating the at least one contact portion of the at least one air-guiding device to a melting point of at least one material component of the contact portion of the air-guiding device
Implementation Method 5
pressing the heated composite part into a geometry of the part with simultaneous formation of an integrally bonded connection between the at least one mating contact portion of the composite part and the contact portion of the air-guiding device
Implementation Method 6
pressing the heated composite part into a geometry of the part with simultaneous formation of an integrally bonded connection between the at least one mating contact portion of the composite part and the contact portion of the air-guiding device
Data Source
AI summary
A method for producing a multi-component part (200) of a vehicle includes inserting an air-guiding device (10) having at least one contact portion (40) into a cavity (310) of a tool (300). The method then includes heating a composite part (100) having at least one mating contact portion (140) to a melting point of at least one material of the composite part (100), and heating the contact portion (40) of the air-guiding device (10) to a melting point of at least one material of the contact portion (40). The method further includes inserting the heated composite part (100) into the cavity (310) of the tool (300) and pressing the heated composite part (100) into a geometry of the part while simultaneously forming an integrally bonded connection between the mating contact portion (140) of the composite part (100) and the contact portion (40) of the air-guiding device (10).