Dielectric Bonding of FRP with Concentrator Electrodes
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Solution Overview
Problem
Current bonding techniques for automotive fiber reinforced plastic (FRP) body members struggle to achieve sufficient rigidity and mechanical strength while maintaining weight reduction, high-quality surface finishes, and reducing manufacturing costs and throughput.
Innovation Solution
A dielectric bonding system using a dielectric heater with opposing electrode plates, a nest with cooling channels, and an interchangeable electrode assembly with concentrator members to apply high-frequency signals and circulate cooling fluids for efficient bonding of FRP body members with reinforcing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If carbon fiber is used to replace glass fiber for weight reduction, then weight savings are achieved, but high quality surface finishes cannot be obtained
Solution Approach 1:
The composite structure is divided into two distinct layers: an outer skin layer containing glass fibers for surface quality and an inner core layer containing carbon fibers for weight reduction. This segmentation allows each layer to fulfill its specific function without compromising the other.
Solution Approach 2:
Different fiber types are placed in different locations within the composite structure. Glass fibers are concentrated in the outer skin layer where surface finish is critical, while carbon fibers are placed in the inner core layer where structural strength and weight savings are prioritized.
2Strength
If reinforcement members are added to FRP body members for rigidity, then mechanical strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The reinforcement members are integrated directly into the molding process by placing them within the mold cavity before injecting the molding composition. This merging of the reinforcement integration step with the molding process eliminates separate assembly operations, reducing manufacturing complexity.
Solution Approach 2:
The molding composition serves multiple functions: it acts as the matrix material, provides the outer skin with surface quality, bonds the reinforcement members, and creates the final composite structure. This multi-functionality reduces the need for additional materials and processes.
3Reliability
If traditional bonding techniques are used for joining layers, then assembly is achieved, but manufacturing throughput is reduced
Solution Approach 1:
The bonding of reinforcement members is achieved continuously during the molding process itself, rather than as a separate post-processing step. The molding composition is injected, cures, and bonds all components in one continuous operation, maximizing manufacturing throughput.
Solution Approach 2:
Reinforcement members are pre-positioned within the mold cavity before the molding composition is injected. This preliminary placement ensures proper positioning and eliminates the need for post-molding alignment or assembly operations.
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 system effectively bonds FRP body members with reinforcing members, providing lightweight, high-strength composite components with improved surface quality and reduced manufacturing costs and cycle times, overcoming issues of disparate layer joining and surface quality.
Implementation Method 1
a dielectric heater having a pair of opposing electrode plates... applying a high frequency signal to the electrodes from the dielectric heater to bond the material assembly together
Implementation Method 2
a nest removably coupled to a first electrode plate of the pair of electrode plates, and an interchangeable electrode assembly removably coupled to a second electrode plate of the pair of electrode plates. The nest has a plurality of cooling channels defined in a body thereof in which a cooling fluid circulates to cool a material assembly that is supported by the nest
Data Source
AI summary
A system and method for dielectric bonding including a dielectric heater having a pair of opposing electrode plates, a nest removably coupled to a first electrode plate of the pair of electrode plates, and an interchangeable electrode assembly removably coupled to a second electrode plate of the pair of electrode plates. The nest having a plurality of cooling channels defined in a body thereof in which a cooling fluid circulates to cool a material assembly that is supported by the nest. The interchangeable electrode assembly having a plurality of concentrator members that are configured to concentrate energy from a voltage source in predetermined locations on the material assembly.