Thermoplastic Encapsulation for Vehicle Chassis Pressure Vessels
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Solution Overview
Problem
Existing vehicle chassis frames face challenges in achieving high rigidity at low weight while maintaining pressure vessel tightness, particularly in cross members subjected to various stresses.
Innovation Solution
A structural component with flange-like ends featuring a form-fitting, gas-tight thermoplastic encapsulation on the outer surface of the flange collar, forming a connection with a thermoplastic pressure vessel body, allowing for a lightweight, high-strength, and gas-tight connection using thermoplastic materials, which can include fiber-reinforced composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel components are used for cross members to ensure high strength and stiffness, then structural integrity is improved, but weight increases leading to higher fuel consumption
Solution Approach 1:
The patent employs composite materials, specifically carbon fiber reinforced plastics (CFRP), to manufacture cross members that replace traditional steel components. These composite cross members achieve comparable or superior strength and stiffness characteristics while significantly reducing weight, thereby lowering fuel consumption and CO2 emissions without compromising structural integrity
2Weight of moving object
If a pressure vessel is integrated into the cross member to reduce weight, then weight is reduced, but ensuring permanent tightness becomes more difficult
Solution Approach 1:
The patent merges the cross member structure with the pressure vessel into a single integrated component. The cross member itself is designed as a hollow pressure-tight structure that serves both as a structural element and as a compressed air reservoir, eliminating the need for separate pressure vessel components and their associated sealing interfaces, thereby ensuring permanent tightness while reducing overall weight
Solution Approach 2:
The cross member is designed to perform multiple functions simultaneously: it provides structural support for the vehicle chassis, serves as a mounting element for other components, and functions as a pressure-tight container for compressed air storage. This multi-functionality reduces the number of separate components needed and simplifies the overall system architecture
3Strength
If fiber-reinforced thermoplastic composite materials are used for the pressure vessel body, then weight is reduced and strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes thermoplastic composite materials that can be processed at relatively low temperatures compared to traditional thermosetting composites. This parameter change in material selection enables the use of automated molding processes and facilitates integration with metal components through techniques such as vibration welding or induction welding, thereby reducing manufacturing complexity while maintaining high strength-to-weight ratio
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 provides a lightweight, high-rigidity structural component that absorbs significant forces and ensures permanent tightness of the pressure vessel, reducing weight and fuel consumption while maintaining structural integrity.
Implementation Method 1
a form-fitting, gas-tight thermoplastic encapsulation on the outer surface of the flange collar
Implementation Method 2
a form-fitting and material-locking and gas-tight thermoplastic connection is formed
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3B
AI summary
The invention relates to a structural component (10', 10") for a chassis frame (100) of a vehicle (N), comprising a flange-type end (10A, 10A-1) at least on one side or flange-type ends (10A, 10A-1) on both sides for securing to the chassis frame (100), which flange-type end/s have a flange collar (10A-2) on the side facing away from the frame. According to the invention, the at least one flange collar (10A-2) has an interlocking, layer-type encapsulation (U1, U2, U3) made of a gas-tight thermoplastic material at least on the outer casing surface, wherein the casing surface of the encapsulation (U1, U2, U3) facing away from the collar forms a connection region (V-AB) with a connection surface to a inner casing surface of an a pressure container body (10B) which is open at least on one side or both sides, and which is also formed at least in the at least one connection region (V-AB) or formed completely from a gas-tight thermoplastic material, such that an interlocking and integral and gas-tight thermoplastic connection is formed in the at least one connection region (V-AB) between the at least one at least partially encapsulated flange collar (10A-2) and the pressure container body (10B) in the assembled state, such that, in the assembled state, the flange-type end (10A, 10A-1) arranged at least on one side and the associated flange collar (10A-2) forms at least one pressure container base (10A, 10A-1, 10A-2) on one side or both sides of the pressure container body (10B).