Composite Junction Structure with Metal Connectors for Welding
Solution Overview
Problem
Current junction technologies for composite materials, such as lap junction structures using adhesives or mechanical bonding, face limitations in increasing bonding strength and productivity, particularly in the assembly of lightweight vehicle parts like Carbon Fiber Reinforced Plastic (CFRP), which require additional thickness or form weak spots, and are not compatible with conventional steel parts, leading to increased manufacturing costs.
Innovation Solution
A composite product with a junction structure featuring metal connectors integrated with composite units, where protrusions and attachment parts form surface contacts for welding, creating a butt junction that maintains a flat surface and avoids the need for additional thickness, allowing for enhanced bonding strength and flexibility in layout configurations without requiring separate holes or exclusive assembly lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a lap junction structure using adhesive is used, then bonding strength is improved, but thickness of the overlap region increases and layout is restricted
Solution Approach 1:
The invention divides the connection system into separate components: a first connector integrated with the first composite unit, and a second connector integrated with the second composite unit. These connectors meet at an interface to form a butt junction, eliminating the need for overlapping layers and adhesive layers, thus reducing thickness while maintaining connection strength.
Solution Approach 2:
The connectors serve as intermediary elements that bridge the two composite units. Instead of directly bonding the composite units together with adhesive (which increases thickness), the metal connectors act as mediators that provide a thin, strong connection interface through welding, reducing the overall junction thickness.
2Ease of manufacture
If mechanical bonding structure with rivets or bolts is used, then assembly is simplified, but weak spots such as fastener holes are formed
Solution Approach 1:
The invention merges the advantages of mechanical bonding (simplicity of integration) with welding (structural integrity). The connectors are integrated with the composite units through mechanical means (insertion into recesses), but the connection between connectors is achieved through welding, eliminating fastener holes and maintaining structural continuity.
Solution Approach 2:
The invention uses composite connection structures: metal connectors with specific material properties (strength, weldability) are combined with composite units. The connectors have attachment parts for mechanical integration and connection parts for welding, creating a hybrid connection system that avoids the weaknesses of pure mechanical bonding.
3Adaptability or versatility
If lap junction structure or mechanical bonding structure is used, then composite units can be connected, but exclusive assembly line is required and manufacturing cost increases
Solution Approach 1:
The invention creates a universal connection system where metal connectors can be used with both composite units and conventional steel parts. The welding process is compatible with conventional steel assembly lines, allowing the same production infrastructure to handle heterogeneous materials (composite-composite, composite-steel), eliminating the need for exclusive assembly lines.
Solution Approach 2:
The invention changes the connection parameters from adhesive-based or fastener-based to welding-based. This parameter change allows the use of conventional welding infrastructure and processes already present in steel assembly lines, making the composite unit connection compatible with existing manufacturing systems without requiring new exclusive assembly lines.
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 improves bonding strength and productivity by forming a stable, flat surface connection that increases design freedom and durability, enabling the use of conventional steel-based assembly lines for heterogeneous vehicle frames while minimizing manufacturing costs and avoiding thickness increases.
Implementation Method 1
the other end of the first connector and the other end of the second connector are joined and fixed by welding
Data Source
AI summary
A composite product having a junction structure includes a first unit formed of a composite material, a first connector formed of a metal and provided with one end inserted into one end of the first unit and formed integrally with the first unit and another end extending outwards from the first unit, a second unit formed of a composite material, and a second connector formed of a metal and provided with one end inserted into one end of the second unit and formed integrally with the second unit and another end extending outwards from the second unit, wherein the other end of the first connector and the other end of the second connector are joined and fixed by welding under a condition that the ends of the first unit and the second unit are opposite each other adjacently.