Fibre-Plastic Composite Profile Connection with Metallic Intermediate Piece

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Solution Overview

Problem

Existing connection arrangements for fiber-reinforced plastic composite profile parts in motor vehicle construction face challenges such as exposure to external influences and inefficiencies in adhesive joining, particularly in terms of thermal expansion and material compatibility.

Innovation Solution

A connection arrangement featuring a metallic intermediate piece with a connecting section that is plugged and glued to a tubular fiber-reinforced plastic profile part, utilizing flow-drilling screws for direct joining without pre-punching, and employing thermal expansion differences to enhance adhesive bonding, while allowing for freewheel zones to accommodate varying thermal expansions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the fiber-reinforced plastic profile part is directly connected to the body frame part, then the connection is simple, but the connection is exposed to external influences and lacks aesthetic appeal

Engineering Contradiction:

Improveconnection structureVSAvoidexposure to external influences

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

A connecting piece is introduced as an intermediary component between the fiber-reinforced plastic profile part and the body frame part. This connecting piece has a connection section that is inserted into the profile part and connected to the body frame part, providing protection against external influences while maintaining structural integrity and aesthetic appearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If adhesive bonding is used to join the profile part to the connecting piece, then the connection is strong, but thermal expansion differences cause bonding failures

Engineering Contradiction:

Improvebond strengthVSAvoidbond reliability under thermal stress

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies adhesive bonding between the connecting piece and the body frame part, utilizing controlled thermal expansion parameters. The adhesive layer accommodates thermal expansion differences between materials, maintaining bond strength while preventing bonding failures under thermal stress conditions.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If conventional drilling methods are used to create connection holes, then precise hole positioning is achieved, but production effort and time increase

Engineering Contradiction:

Improvehole positioning accuracyVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The connection piece is designed with self-centering features that enable automatic hole alignment during assembly. This self-service mechanism eliminates the need for precise pre-drilling and complex positioning fixtures, achieving both accurate hole positioning and high production efficiency through simplified manufacturing processes.

Inventive Principle:

Principle #25Self-service

4Strength

If the connecting piece is made of metal, then strength and durability are improved, but corrosion risks increase

Engineering Contradiction:

Improveconnecting piece strengthVSAvoidcorrosion

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The connecting piece is constructed using composite materials or metal alloys with enhanced corrosion resistance. This approach maintains the high strength and durability requirements while mitigating corrosion risks through material composition optimization, creating a balanced solution that addresses both mechanical performance and environmental resistance.

Inventive Principle:

Principle #40Composite materials

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 provides a robust, cost-effective, and aesthetically appealing connection that is resilient to external influences, reduces production effort, and allows for easy automation, while minimizing material stress and corrosion risks.

Implementation Method 1

the end of the fiber-reinforced plastic profile part designed as a tubular hollow profile is plugged onto the connecting section of the intermediate piece and is bonded to this connecting section on its inner surface

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

employing thermal expansion differences to enhance adhesive bonding, while allowing for freewheel zones to accommodate varying thermal expansions

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP3174777B1Connection arrangement between a fibre-plastic composite profiled part and a vehicle body frame part and method for producing same

Publication Date: 2019.03.27 BAYERISCHE MOTOREN WERKE AG

Figure 1~2
Figure 3~4b

AI summary

The invention relates to a connection arrangement (10) between a fibre-plastic composite profiled part (21) and a vehicle body frame part (31), comprising an intermediate piece (40) connected to the vehicle body frame part (31), wherein the intermediate piece (40) has a connection portion (41) which is plug-connected and adhesively bonded to an end of the fibre-plastic composite profiled part (21). Provision is made for the end of the fibre-plastic composite profiled part (21) to be plugged onto the connection portion (41) of the intermediate piece (40) and to be adhesively bonded on the inner surface to the connection portion (41). The invention further relates to a method for producing such a connection arrangement (10) and to a preferred use.