CFRP Vehicle Body Fastening via Epoxy Resin Interconnecting Web
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Solution Overview
Problem
Carbon fiber reinforced plastic (CFRP) components in vehicle bodies face challenges in precision bending and fastening due to material limitations, which result in reduced stiffness and require costly milling for hole creation, making conventional fastening methods difficult.
Innovation Solution
A flat vehicle body component with an interconnecting web made of epoxy resin, allowing for a force-locking mounting part with holes for fastening additional components without compromising stiffness, using a metal sheet mounting part that clamps securely onto the interconnecting web, enabling conventional fastening methods like bolts or screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If holes are milled into the CFRP component for fastening, then components can be fastened to the CFRP, but the carbon fibers are separated and the stiffness of the CFRP component is considerably reduced
Solution Approach 1:
A mounting part made of sheet metal acts as an intermediary between the CFRP component and the component to be fastened. The mounting part is attached to the CFRP component via adhesive in a recess, avoiding direct hole drilling into the CFRP. This mediator allows conventional fastening methods to be used while preserving the integrity and stiffness of the CFRP structure.
Solution Approach 2:
The fastening system is divided into separate functional elements: the CFRP component with a recess, the mounting part with fastening elements, and the component to be fastened. This segmentation allows each element to be optimized independently - the CFRP maintains its structural integrity while the mounting part provides the necessary fastening capability through integrated fastening elements.
2Productivity
If holes are punched out in sheet metal components, then fastening is simple and quick, but this method cannot be applied to CFRP components without milling
Solution Approach 1:
The mounting part is pre-formed with integrated fastening elements (such as punched holes or formed features) during the stamping process. This preliminary action allows the mounting part to be prepared in advance with all necessary fastening features, enabling quick assembly to the CFRP component without time-consuming milling operations at the final assembly stage.
Solution Approach 2:
The complex mechanical process of milling holes in CFRP is replaced by a simpler adhesive bonding process. The mounting part with pre-formed fastening elements is attached to the CFRP component using adhesive in a recess, substituting the mechanical hole-creation process with a chemical bonding process that is faster and less damaging to the CFRP structure.
3Adaptability or versatility
If conventional fastening methods are used directly on CFRP, then no additional parts are needed, but the CFRP material limits the shape and fastening options
Solution Approach 1:
The mounting part is formed through plastic deformation (bending, shaping) during the stamping process, allowing it to adapt to different geometries and configurations. This parameter change in the mounting part's shape enables it to accommodate various fastening requirements and CFRP component shapes without limiting the CFRP material's geometric freedom.
Solution Approach 2:
The mounting part serves multiple functions: it provides structural support, enables conventional fastening methods through integrated fastening elements, and adapts to different CFRP component shapes. This multi-functionality makes the mounting part a versatile solution that can be applied to various fastening scenarios without requiring different approaches for each CFRP geometry.
Data Source
AI summary
A flat vehicle body component made of a carbon fiber reinforced plastic has at least one interconnecting web that protrudes from the flat vehicle body component and that is made entirely of the matrix material epoxy resin. A mounting part at least partially envelops the interconnecting web in a force locking manner, so that the mounting part is clamped securely on the interconnecting web. The mounting part has at least one hole that can be used for fastening another component. An additional component may be fastened in the hole in a conventional manner, so that the carbon fiber reinforced plastic component does not need corresponding holes. The interconnecting web may be integrally molded on the vehicle body component during its manufacture so that practically no additional engineering effort is needed.