Composite Vehicle Body Panel With Steel Flange For Welding
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Solution Overview
Problem
The use of fiber reinforced plastic panels in vehicle body construction is hindered by the inability to be welded to steel panels, leading to increased manufacturing costs and potential delamination issues, as well as reduced bonding strength compared to traditional welding methods.
Innovation Solution
A composite vehicle body panel is created by integrating a steel flange with a fiber reinforced plastic panel, where the steel flange has foaming portions and a stepped design, allowing for welding and improved load distribution, and is manufactured through a process involving foaming, punching, and bonding with foamed plastics and resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber reinforced plastic panels are used to reduce weight, then weight is reduced, but welding capability is lost requiring mechanical fastening methods
Solution Approach 1:
The invention uses a composite structure combining fiber reinforced plastic panel with a steel flange. The steel flange provides welding capability while the fiber reinforced plastic maintains weight reduction benefits. This composite approach allows the panel to be welded to the vehicle body through the steel flange portion.
Solution Approach 2:
The vehicle body panel is divided into two functional parts: the fiber reinforced plastic panel for weight reduction and the steel flange for welding and structural connection. This segmentation allows each material to perform its optimal function.
2Strength
If mechanical fastening methods are used to attach fiber reinforced plastic panels, then welding capability is maintained in steel parts, but manufacturing cost increases due to additional process steps
Solution Approach 1:
The steel flange integrated with the fiber reinforced plastic panel allows welding connection to the vehicle body, eliminating the need for mechanical fastening methods like bolts and nuts. This reduces manufacturing complexity and cost while maintaining strong structural connection.
3Ease of operation
If fastening holes are formed in fiber reinforced plastic panels for mechanical attachment, then connection is enabled, but delamination occurs reducing structural integrity
Solution Approach 1:
By using a steel flange instead of forming holes in the fiber reinforced plastic panel, the invention avoids delamination issues. The steel flange provides the attachment function through welding without compromising the integrity of the composite panel.
4Ease of operation
If bolts and nuts are used to fasten fiber reinforced plastic panels to steel panels, then connection is achieved, but bonding strength is reduced compared to welding
Solution Approach 1:
The steel flange enables welding connection between the fiber reinforced plastic panel and the vehicle body, providing bonding strength equivalent to traditional steel-to-steel welding while still allowing the use of fiber reinforced plastic for weight reduction.
Data Source
AI summary
A composite vehicle body panel includes a fiber reinforced plastic panel and a steel flange disposed in the fiber reinforced plastic panel and having an edge protruding outward from the fiber reinforced plastic panel beyond an outer edge of the fiber reinforced plastic panel. The composite vehicle body panel can be used in vehicle structures manufactured on standard vehicle productions lines, thereby easing vehicle manufacturing, improving productivity, and providing increased rigidity to the vehicle bodies. A method of manufacturing the composite vehicle body panel and a vehicle structure using the panel are also provided.