Fiber Composite Mounting Part for Integral Vehicle Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of metallic mounting parts in fiber composite parts of motor vehicles requires costly adhesion promoters and anti-corrosion coatings, increasing manufacturing expenses and not ensuring an integral bond with the adjoining components.
Innovation Solution
Incorporating fiber composite mounting parts made from carbon or glass fiber reinforced polymers with relatively short fibers, eliminating the need for coatings and allowing for a strong, three-dimensionally shaped bond with the fiber composite part, manufactured through a curing process in a mold at defined temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic mounting parts are used in fiber composite parts, then the structural strength and three-dimensional shape are ensured, but manufacturing expenses increase due to required adhesion promoters and anti-corrosion coatings
Solution Approach 1:
The mounting part is made from the same fiber composite material as the surrounding structure, creating material homogeneity. This eliminates the need for adhesion promoters and anti-corrosion coatings, reducing manufacturing complexity and cost while maintaining structural strength.
Solution Approach 2:
The invention uses fiber composite material (e.g., carbon fiber reinforced polymer or glass fiber reinforced polymer) for the mounting part instead of metal. This composite material provides the necessary strength while being inherently compatible with the fiber composite structure, eliminating additional coating requirements.
2Shape
If metallic mounting parts are used, then the three-dimensional shape is achieved, but the bond with fiber composite part is not integral
Solution Approach 1:
Using the same fiber composite material for both the mounting part and the surrounding structure ensures material compatibility and creates an integral bond. The homogeneous material composition eliminates interfacial weaknesses that would exist between dissimilar materials like metal and fiber composite.
Solution Approach 2:
The mounting part is manufactured as an integrated component of the fiber composite structure through a single molding process. This merging of the mounting part with the surrounding structure creates a seamless, integral bond without separate assembly steps or potential failure interfaces.
3Ease of manufacture
If fiber composite mounting parts with short fibers are used, then manufacturing cost is reduced, but the strength may be compromised
Solution Approach 1:
The invention optimizes the fiber length parameter to a specific range (3-100 mm, preferably 20-80 mm) that balances manufacturing ease with structural strength. This parameter optimization allows the use of short fibers (reducing cost and simplifying manufacturing) while maintaining sufficient strength through appropriate fiber length selection.
Solution Approach 2:
The fiber length and distribution are optimized specifically for the mounting part application. The short fibers are sufficient for the localized strength requirements of the mounting part while keeping the overall structure cost-effective and manufacturable, rather than using long continuous fibers throughout.
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 solution reduces manufacturing costs and ensures a strong, integral bond between the mounting parts and the fiber composite parts, replicating the strength and shape of metallic parts without the need for additional coatings.
Implementation Method 1
The mixture then is filled into a three-dimensionally shaped mold for the mounting part. The mold then is closed and the mounting part is cured for a defined period of time at a defined temperature and a defined pressure.
Data Source
AI summary
A mounting part (11) for affixing a composite fiber part of a motor vehicle to at least one adjoining component of a motor vehicle is made from a fiber composite material. The mounting part (11) has a three-dimensionally shape that defines ribs and/or webs and/or protrusions and/or depressions.