Thermoplastic Latching Device for CFRP Substructure Installation
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Solution Overview
Problem
The installation of fiber composite components, such as CFRP, in vehicles is complicated and costly due to the lack of elasticity in thermosetting materials, making adhesive bonding processes time-consuming and requiring precise orientation before securing.
Innovation Solution
A latching device with a deformable latching element is attached to the component via injection molding, allowing for rapid and reliable installation using a latching connection, which is particularly advantageous for thermosetting materials like CFRP, enabling alignment and a secure, form-fitting connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding processes are used to fasten thermosetting components, then reliable connection is achieved, but installation time and process complexity increase significantly
Solution Approach 1:
The patent changes the material parameter of the fastening element from thermosetting (inelastic) to thermoplastic (elastic), enabling reversible deformation. This allows the fastening element to be elastically deformed during insertion and then lock into place, providing reliable connection without requiring time-consuming adhesive bonding processes
Solution Approach 2:
The patent replaces the chemical adhesive bonding system with a mechanical latching system. The thermoplastic fastening element uses elastic deformation and mechanical interlocking to achieve reliable connection, eliminating the need for adhesives and the associated time-consuming orientation and bonding processes
2Reliability
If adhesive bonding is used to connect thermosetting components, then secure connection is achieved, but process complexity and orientation requirements increase
Solution Approach 1:
The patent changes the material parameter of the fastening element from thermosetting to thermoplastic, giving it elastic properties. This allows the fastening element to deform and lock mechanically into place, providing secure connection without requiring precise orientation or complex adhesive bonding processes
Solution Approach 2:
The patent replaces the complex chemical adhesive bonding system with a simple mechanical latching system. The thermoplastic fastening element achieves secure connection through elastic deformation and mechanical interlocking, eliminating orientation requirements and process complexity
3Stability of the object's composition
If thermosetting materials are used for components, then high stability and low weight are achieved, but elasticity and ease of installation are lost
Solution Approach 1:
The patent segments the component system into two parts: the thermosetting component (providing stability and low weight) and the separate thermoplastic fastening element (providing elasticity and ease of installation). This segmentation allows each part to have optimized properties without compromising the other
Solution Approach 2:
The thermoplastic fastening element acts as an intermediary between the thermosetting component and the mounting structure. It provides the necessary elasticity and deformability for easy installation while the thermosetting component maintains its stability and weight advantages
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 enables rapid, reliable, and cost-effective installation of thermosetting components like CFRP, providing a stable and durable connection while maintaining the material's thermal and mechanical properties, and allowing for the use of thermoplastics for the latching device to ensure flexibility and ease of production.
Implementation Method 1
The first component is inserted into an injection molding device. The first component is insert molded at least in sections with at least one reversibly deformable material in the injection molding device.
Implementation Method 2
The first component is particularly preferably at least partially formed from a thermosetting material. In particular, the first component is formed from a thermosetting plastic or from a thermoset. Such a first component provides high as stability at a correspondingly low weight. In addition, a component made of such a material is particularly thermally stable.
Data Source
AI summary
A method for producing a vehicle substructure with at least one first component, and also a vehicle substructure, are described herein. The first component is connectable to a second component by an installation connection. The first component is manufactured from a material which is not suitable for reversible deformations. A latching device having a deformable latching element is attached here to the first component. For this purpose, the first component is inserted into an injection molding device and is insert-molded with a reversibly deformable plastic. The latching device is produced here by injection molding and attached to the first component.