Fibre Composite Chassis Component with Overlapping Layers for Gradual Failure
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Solution Overview
Problem
Components made of continuous fiber-reinforced plastics used in vehicle chassis, such as wheel-guiding links, exhibit abrupt failure under tensile overload, leading to undesirable complete loss of load-bearing capability, and lack control over load-carrying behavior during or after damage events.
Innovation Solution
A component with sections made of fiber composite material featuring overlapping layers of unidirectional fibers aligned in the tensile direction, connected via a plastic matrix, allowing for gradual failure and continued functionality by unfolding when overloaded, with optional reinforcement and filling materials to adjust force-displacement behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber-reinforced plastics are used in chassis components, then weight is reduced and strength is improved, but the component exhibits abrupt failure under tensile overload with complete loss of load-bearing capability
Solution Approach 1:
The fiber reinforcement is segmented into multiple discrete layers rather than using continuous fiber bundles. Each layer can fail independently, transforming the abrupt single-point failure of continuous fibers into a gradual multi-stage failure process where load-bearing capability is progressively reduced rather than completely lost.
Solution Approach 2:
The invention changes the structural parameter of the fiber reinforcement from continuous to discontinuous layered configuration. This parameter change enables the material to exhibit progressive damage accumulation and gradual failure behavior, allowing the component to maintain partial load-bearing capability even after significant damage occurs.
2Productivity
If continuous fiber-reinforced plastics are used, then manufacturing efficiency is improved, but control over load-carrying behavior during damage events is lost
Solution Approach 1:
Different regions of the component are designed with different fiber layer configurations. The overlapping area contains multiple layers that can fail progressively, while other regions maintain standard reinforcement. This local differentiation enables targeted control over load-carrying behavior in specific zones without compromising overall manufacturing efficiency.
Solution Approach 2:
The invention uses a composite structure combining multiple fiber layers with a plastic matrix in a specific overlapping configuration. This composite arrangement provides both the manufacturing efficiency of fiber-reinforced plastics and the adaptability to control failure behavior through the layered overlap design, enabling gradual failure and continued functionality.
3Reliability
If separate overload elements are installed to prevent abrupt failure, then reliability is improved, but device complexity and weight increase
Solution Approach 1:
The overload protection function is merged into the primary structural component itself through the overlapping fiber layer design. Instead of adding separate overload elements, the component's own structure incorporates the gradual failure mechanism, eliminating the need for additional parts and reducing overall device complexity while maintaining reliability.
Solution Approach 2:
The overlapping fiber layer structure serves multiple functions simultaneously: it provides the primary load-bearing capability during normal operation and acts as an overload protection mechanism during damage events. This multi-functionality eliminates the need for separate dedicated overload elements, reducing component complexity while improving reliability.
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
Enables partial maintenance of function under tensile overload, reduces weight compared to separate overload elements, and achieves high energy absorption with adjustable failure behavior, allowing for targeted design of force-displacement characteristics.
Implementation Method 1
connected to each other via the plastic matrix of the fiber composite material
Implementation Method 2
achieves high energy absorption with adjustable failure behavior, allowing for targeted design of force-displacement characteristics
Data Source
AI summary
The invention relates to a component, at least sections of which are formed from a fibre composite, for example of a vehicle, and which is provided there in particular in the chassis region, which component has a section which is designed for an overload in respect of tensile loading and is formed by a flat strip (1) folded in a plurality of layers one above another, or by an open or closed profile of a semi-finished fibre product (1) or a fibre composite (1), the profile overlapping in a plurality of cohesive layers which are connected to one another via the plastics matrix of the fibre composite.