Composite Link Reinforcement with 3D Metal Inserts
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Solution Overview
Problem
Composite structures for automobile seats, particularly the link between a seat bottom and backrest, face challenges in resisting crash tests due to inadequate reinforcement, especially when impacted from the rear along the vehicle's axis X.
Innovation Solution
The composite structure incorporates a reinforcing design with metal inserts featuring three-dimensional shapes, including planar wings and bases with textures and holes, combined with preimpregnated continuous fiber thermoplastic layers on the outer surface, strategically positioned to enhance anchoring and tensile resistance, and overmolding with thermoplastic reinforced with cut fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple metal insert design is used, then the device complexity is reduced, but the strength and crash resistance of the composite structure deteriorates
Solution Approach 1:
The metal insert transitions from a simple planar design to a three-dimensional structure with wings extending in multiple directions. The first wing extends perpendicular to the base toward the inside of the composite structure, while the second wing extends perpendicular to both the base and the first wing, creating a spatial reinforcement pattern that resists crash forces from multiple angles.
Solution Approach 2:
The solution combines metal inserts with organo (preimpregnated continuous fiber thermoplastic) and overmolding with cut fibers. The metal insert provides rigid structural support, while the thermoplastic materials provide ductility and energy absorption, creating a composite reinforcement system that withstands crash impacts.
2Strength
If reinforcement is added to improve crash resistance, then the strength is improved, but the device complexity increases
Solution Approach 1:
The reinforcement system is divided into distinct functional components: the metal insert base for anchoring, the first wing for internal reinforcement, the second wing for external reinforcement, and the thermoplastic overmolding. Each segment serves a specific purpose in resisting crash forces, allowing for optimized performance without unnecessary complexity.
Solution Approach 2:
The reinforcement features are strategically positioned at specific locations: the first wing extends toward the inside of the composite structure where internal support is needed, while the second wing extends toward the outside where external reinforcement is required. This localized reinforcement approach optimizes crash resistance where most needed.
3Reliability
If the first wing extends toward the inside of the structure, then the anchoring is improved, but the manufacturing difficulty increases
Solution Approach 1:
The metal insert with its three-dimensional wing structure is prepared in advance before being integrated into the composite structure. The insert is formed with the appropriate geometry and then positioned and anchored in the predetermined location, allowing for precise placement and reliable anchoring without complex assembly operations.
Data Source
AI summary
A composite structure comprising a substantially planar portion and a border arranged on the border of the substantially planar portion. A first linking zone arranged at one end of the border along a first axis and able to accommodate a first metal insert and a second linking zone arranged at another end of the border along the first axis and able to accommodate a second metal insert symmetrical to the first metal insert. An insert comprises a substantially planar base arranged perpendicular to the first axis and comprising, substantially at a center of the substantially planar base, a piercing. A first substantially planar wing is arranged perpendicular to the substantially planar base and a second substantially planar wing arranged perpendicular to the substantially planar base and the first substantially planar wing.