Composite Vehicle Body Part Thermal Expansion Coordination
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Solution Overview
Problem
Composite vehicle body parts experience deformation due to differing thermal expansion behaviors of individual material layers, leading to issues such as bulging or warping when temperature changes occur.
Innovation Solution
The coefficients of thermal expansion of the barrier layer and carrier structure are carefully coordinated to minimize deformation within a temperature range of -50°C to 80°C, ensuring the composite component maintains its form and functionality by using a polyurethane/glass fiber mixture for the covering layers and a honeycomb core with strategically selected fiber proportions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual layers are composed of different materials to achieve specific functional requirements, then the functional performance of the composite component is improved, but deformation occurs due to different lateral expansion behaviors of the layers when temperature changes
Solution Approach 1:
The patent applies parameter changes by carefully selecting and coordinating the coefficients of thermal expansion of different materials used in the barrier layer and carrier structure. By adjusting material composition and physical parameters, the invention achieves compatible thermal expansion characteristics between layers, preventing deformation while maintaining functional performance across temperature ranges from -50°C to +80°C
Solution Approach 2:
The invention utilizes composite materials with specifically coordinated thermal properties. The barrier layer and carrier structure are designed as composites where the materials are selected not only for functional requirements but also for their thermal expansion compatibility, creating a multi-material system that maintains dimensional stability under temperature variations
2Adaptability or versatility
If the composite component is designed with multiple material layers to achieve lightweight construction and specific functions, then the component's functional versatility is improved, but the structural stability under temperature variation deteriorates
Solution Approach 1:
The invention addresses structural stability by changing the thermal parameters of the materials used. The coefficients of thermal expansion of the barrier layer and carrier structure are specifically coordinated to match within a certain range, ensuring that the composite component maintains its structural stability and dimensional integrity across the operating temperature range of -50°C to +80°C
Solution Approach 2:
The patent employs composite materials with coordinated thermal properties to maintain structural stability. The barrier layer and carrier structure are designed as a composite system where material selection considers both functional requirements and thermal expansion compatibility, preventing warping or bulging while preserving the lightweight and multi-functional characteristics
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 coordinated thermal expansion strategy effectively prevents undesirable deformation, maintaining the structural integrity and design of the composite component across the specified temperature range, making it suitable for various vehicle and non-vehicle applications.
Implementation Method 1
the barrier layer and the carrier structure have coefficients of thermal expansion selected such that deformation of the material composite in the event of a temperature change within a range of between −50° C. and +80° C. is at least largely absent
Data Source
AI summary
A flat composite component, in particular a vehicle body part, comprising a material composite having an outer layer, a barrier layer adjoining the outer layer and a carrier structure on which the barrier layer is arranged and which comprises a core which has a first cover layer on the side facing the barrier layer and a second cover layer on the side facing away from the barrier layer. According to the invention, the barrier layer and the carrier structure have thermal expansion coefficients which are selected such that a deformation of the material composite in the case of a temperature change at least largely stops in a range between −50° C. and +80° C.