Fiber-Reinforced Vehicle Component Manufacturing with Intermediary Layer
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Solution Overview
Problem
Multi-material components, such as those made of aluminum and carbon fiber-reinforced plastic (CFRP), face issues with corrosion resistance, inhomogeneous material properties leading to stiffness and strength variations, differing coefficients of expansion causing climate resistance challenges, and adhesion limitations, while thermoplastic components suffer from strength loss due to water absorption and temperature sensitivity.
Innovation Solution
A method involving the production of vehicle components using a duroplastic material for both the connecting strut and bearing bush, combining compression molding and injection molding techniques to achieve high stability and temperature resistance, eliminating the need for additional sealing and allowing for independent alignment of bearing axes, and incorporating elastomeric bearings for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum and CFRP multi-material components are used, then weight reduction is achieved, but corrosion resistance deteriorates due to galvanic corrosion between aluminum and carbon fibers
Solution Approach 1:
An intermediate layer made of glass fiber textile is introduced between the aluminum bearing bushing and the carbon fiber reinforcement. This intermediate layer acts as a mediator that prevents direct contact between dissimilar metals and carbon fibers, thereby eliminating galvanic corrosion while maintaining the weight benefits of the multi-material construction.
2Weight of moving object
If aluminum bearing bushing is used with CFRP laminate, then weight reduction is achieved, but adhesion deteriorates due to lack of chemical bonding
Solution Approach 1:
The glass fiber textile intermediate layer provides both mechanical interlocking and chemical bonding capabilities. It adheres to both the aluminum bearing bushing and the carbon fiber reinforcement, creating strong chemical bonds that overcome the adhesion limitations of direct aluminum-CFRP contact.
3Reliability
If additional intermediate layer is used for corrosion protection, then corrosion resistance is improved, but manufacturing complexity increases due to additional work steps
Solution Approach 1:
The intermediate layer, bearing bushing, and CFRP reinforcement are combined into a single integrated component using compression molding. This merging of previously separate manufacturing steps into one process reduces overall manufacturing complexity despite the addition of the intermediate layer.
Solution Approach 2:
The intermediate layer is pre-positioned between the bearing bushing and CFRP reinforcement before the final compression molding step. This preliminary arrangement ensures proper alignment and integration without requiring complex assembly operations after molding.
4Weight of moving object
If aluminum bearing bushing is used, then weight reduction is achieved, but manufacturing complexity increases due to complex sealing and positioning requirements
Solution Approach 1:
The bearing bushing, intermediate layer, and reinforcement are molded as a single integrated component, eliminating the need for separate sealing elements and positioning mechanisms. The compression molding process itself provides the necessary sealing and alignment functions.
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 method produces components with improved long-term stability, temperature resistance, and corrosion protection, addressing the limitations of multi-material components and thermoplastic weaknesses by ensuring a durable and reliable chassis component.
Implementation Method 1
producing the connecting strut by impregnating the fiber preform with a duroplastic material, which is injected and/or introduced into the injection mold, in particular by injection molding
Implementation Method 2
producing a bearing bush by pressing the fiber matrix semi-finished product
Implementation Method 3
incorporating elastomeric bearings for enhanced performance
Data Source
Figure 1~4
Figure 5~8
Figure 9~12
AI summary
Method for manufacturing a vehicle component, involving the steps of: introducing a semi-finished fiber matrix product (24) having a thermosetting matrix into a pressing mold; making a bearing bush (4) by pressing the semi-finished fiber matrix product (24); making a fiber preform (20) for a connecting strut (8); introducing the fiber preform (20) into an injection mold; making the connecting strut (8) by impregnating the fiber preform (20) with a thermosetting material which is injected into the injection mold for this purpose; and permanently joining the connecting strut (8) to the bearing bush (4).