Composite Structural Member Hollow Cross-Section Bonding
Solution Overview
Problem
Existing composite material structural members with complex external shapes face challenges in achieving high-strength, closed cross-sectional structures, particularly in vehicular applications where flat plate-shaped sandwich panels are difficult to apply, limiting their use in components requiring high strength and rigidity.
Innovation Solution
A composite material structural member is manufactured by adhering composite material members around a core member to form a hollow space, with a composite material sheet overlapping the bonded portion between the members, creating a high-strength, closed cross-sectional structure through a lamination and curing process, enhancing the structural integrity and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat plate-shaped sandwich panels are used to form composite material structural members, then manufacturing is simplified, but the structure cannot achieve high-strength closed cross-sectional configuration for complex external shapes
Solution Approach 1:
The structural member is divided into multiple members that are adhered together to form a closed cross-sectional structure. Each member can be manufactured separately and then assembled, enabling complex external shapes while maintaining manufacturing feasibility through modular construction.
Solution Approach 2:
The invention uses composite material sheets impregnated with thermosetting matrix resin to adhere the members together. The composite material provides both structural strength and bonding functionality, creating a high-strength closed cross-sectional structure suitable for complex external shapes.
2Strength
If members are adhered together to form closed cross-sectional structure, then strength and rigidity are improved, but the bonded portion becomes a vulnerable portion prone to breakage
Solution Approach 1:
The composite material sheet is specifically positioned to overlap the bonded portions between members. This local reinforcement concentrates strength exactly where the bonded joints are most vulnerable, preventing breakage at the adhesive interfaces while maintaining the overall closed cross-sectional structure.
Solution Approach 2:
The composite material sheet is placed in advance at the bonded portions to prevent future breakage. This preemptive reinforcement ensures that the vulnerable adhesive joints are protected before loading occurs, enhancing the reliability of the bonded portions.
3Reliability
If composite material sheets are added to reinforce bonded portions, then reliability of bonded portions is improved, but manufacturing complexity increases
Solution Approach 1:
The composite material sheet serves dual functions: it reinforces the bonded portions to prevent breakage and simultaneously acts as the adhesive medium to join members together. This merging of reinforcement and bonding functions into a single component simplifies the overall manufacturing process despite the added reinforcement function.
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 method allows for the creation of composite material structural members with improved strength and rigidity, capable of withstanding various loads and preventing breakage at the bonded interface, even in complex external shapes, thereby enhancing the structural performance and reducing material usage.
Implementation Method 1
laminating a composite material sheet in an area that is on an outer peripheral surface of the core member and that overlaps at least a bonded portion between the members
Implementation Method 2
heating and curing the layered structure
Data Source
AI summary
A composite material structural member including a core member, composite material members, and at least one composite material sheet. The members are disposed around the core member and are adhered to each other to form a hollow space. The composite material sheet is disposed between the core member and the members so as to overlap the bonded portion between the members. The composite material sheet forms a hollow composited structure together with the members.