Composite Component with Metallic Pin Insert for Impact Resistance
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Solution Overview
Problem
Fiber-composite materials have limited stability, leading to severe deformation or fragmentation during collisions, such as vehicle crashes, due to inadequate energy absorption and distribution.
Innovation Solution
A composite component comprising a continuous-filament reinforced thermoplastic material with a metallic insert having a pin structure, where the pins penetrate into the thermoplastic material, enhancing energy absorption and distribution across the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-composite materials are used for lightweight construction, then weight is reduced, but stability and resistance to deformation during collision deteriorate
Solution Approach 1:
The patent combines fiber-composite material (continuous filaments in thermoplastic matrix) with a metallic insert containing pins to create a hybrid composite structure. This allows the component to maintain lightweight properties while the metallic pins provide enhanced stability and energy absorption during collisions, resolving the contradiction between weight reduction and stability maintenance.
2Device complexity
If fiber-composite materials are used, then energy absorption capability is limited, but this is necessary to maintain material simplicity
Solution Approach 1:
By integrating a metallic insert with pins into the fiber-composite structure, the patent creates a composite material system where the metallic pins specifically enhance energy absorption during impact. The pins deform plastically and distribute impact forces, significantly improving energy absorption capability while maintaining relatively simple manufacturing through insertion molding or similar processes.
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 pin structure within the composite component effectively counters deformation by absorbing and distributing impact energy, resulting in improved stability and impact resistance.
Implementation Method 1
The pins of the pin structure penetrate into the thermoplastic material
Implementation Method 2
The pins of the pin structure penetrate into the thermoplastic material in order to materially bond the insert to the thermoplastic material. In this way, the pin structure within the composite component counters deformation, for example during a collision
Data Source
AI summary
A composite component has a continuous-filament reinforced thermoplastic material (1) and a metallic insert (2), which is obtainable in that (a) a metallic insert (2) having pin structures (3) attached to the surface is provided, (b) firstly the pinned metallic insert (2) is inserted into a forming tool, (c) subsequently an optionally pre-heated organic sheet (1) manufactured from the continuous-filament reinforced thermoplastic (1) is disposed thereon, (d) the forming tool is closed and subsequent to a dwell time is optionally cooled to room temperature, and finally (e) the composite component (4) thus obtained is removed, is proposed.