Composite Connecting Rod Adhesive Bonding
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Solution Overview
Problem
Existing connecting rods for combustion engines, particularly those made of composite materials, face challenges in durable connection elements between two-piece configurations, leading to increased manufacturing complexity and cost, as well as insufficient durability and weight reduction opportunities.
Innovation Solution
A connecting rod design featuring an adhesive connection between two composite material parts, eliminating the need for traditional connection elements, allowing for a lighter, more durable construction with reduced stress and enabling easier disassembly for maintenance, using carbon fiber reinforced resin and optimized surface geometries for enhanced shear force resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional connection elements (bolts, threads) are used to connect two-piece composite connecting rod parts, then the connecting rod can be assembled and disassembled for maintenance, but the connection durability is insufficient and the manufacturing becomes more complex and costly
Solution Approach 1:
The patent replaces traditional mechanical connection elements (bolts, threads, rivets) with an adhesive bonding system. The adhesive layer chemically bonds the two composite connecting rod parts together, providing a connection that is more durable and integrated than mechanical fasteners while maintaining the ability to disassemble for maintenance through controlled adhesive degradation or heating.
Solution Approach 2:
The patent changes the physical and chemical parameters of the connection interface by using adhesive with specific properties (viscosity, curing temperature, bond strength). The adhesive parameters are optimized to provide sufficient bond strength for engine operation while allowing for controlled disassembly when needed, resolving the contradiction between durability and maintainability.
2Reliability
If metal connection elements are embedded within composite material to improve connection durability, then the connection strength increases, but the manufacturing becomes more labor intensive and cost intensive
Solution Approach 1:
The patent eliminates the need for embedded metal thread parts and mechanical connection elements by using adhesive bonding throughout the composite structure. This allows for continuous fiber reinforcement and streamlined manufacturing of the two-piece connecting rod assembly without the labor-intensive processes of embedding metal inserts or drilling threaded holes in composite materials.
Solution Approach 2:
The patent uses composite materials (carbon fiber reinforced polymer) for both connecting rod parts and employs adhesive bonding that is compatible with the composite structure. This eliminates the need to embed metal connection elements in the composite, as the adhesive itself provides the necessary connection strength while maintaining the composite material's properties and allowing for more efficient manufacturing processes.
3Strength
If traditional metal connecting rods are used, then the connection elements provide sufficient strength, but the weight of the connecting rod is high
Solution Approach 1:
The patent uses composite materials (carbon fiber reinforced polymer) for the connecting rod parts instead of traditional metal materials. The adhesive bonding system provides sufficient connection strength to replace metal mechanical fasteners, enabling the use of lightweight composite materials while maintaining the structural integrity and strength requirements for connecting rod application.
Solution Approach 2:
The patent replaces heavy metal mechanical connection elements with a lightweight adhesive bonding system. The adhesive provides the necessary connection strength without the weight penalty of metal bolts, threads, or rivets, enabling significant weight reduction in the connecting rod assembly while maintaining connection durability.
4Strength
If connection elements such as bolts are used to connect the two connecting rod parts, then the parts can be securely joined, but the connection requires pre-tensioning that increases stress on the connecting rod
Solution Approach 1:
The patent replaces mechanical bolt connections that require pre-tensioning with an adhesive bonding system. The adhesive cures to form a rigid bond that provides connection strength without requiring the high pre-tension forces that bolts need to maintain clamping pressure. This eliminates the additional stress on the connecting rod that would otherwise be imposed by bolt pre-tensioning.
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 adhesive connection reduces the weight of the connecting rod by over 50% compared to metal rods, decreases energy consumption, and enhances engine efficiency by minimizing friction and resistance, while allowing for a more streamlined design and simplified assembly/disassembly processes.
Implementation Method 1
a connection between the first and the second connecting rod parts is an adhesive connection
Implementation Method 2
The first and the second connecting rod parts are manufactured from a composite material
Data Source
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AI summary
The invention relates to a method for assembly, a method for disassembly and a connecting rod (1) for a combustion engine, the connecting rod (1) comprising a first and a second connecting rod part (2, 3), wherein the first connecting rod part (2) is configured to be connected to the second connecting rod part (3) when the connecting rod (1) is assembled around a rod-bearing journal of a crankshaft, wherein a connection between the first and the second connecting rod parts (2, 3) is an adhesive connection.