Fibre Composite Ring Beam Connection Method
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Solution Overview
Problem
Conventional methods for connecting metallic elements to fibre composite ring beams in rail vehicle head modules damage the fibre structure during boring and risk electrochemical corrosion, compromising the structural integrity and safety in crash scenarios.
Innovation Solution
The method involves positioning metallic connecting elements in the unconsolidated state within the fibre-reinforcing structure of the ring beam, allowing them to penetrate without damaging the fibres, and using a design that completely or partially surrounds the ring beam ends with washers or shims to prevent direct contact and corrosion, while ensuring secure attachment through screw or rivet connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic connecting elements are inserted into the ring beam after consolidation, then the connection is secure, but the fibre structure is damaged during boring
Solution Approach 1:
The metallic connecting elements are positioned in the unconsolidated fibre-reinforcing structure before the matrix material is applied and consolidated. This preliminary positioning allows the fibres to be arranged around the connecting elements without damage, and the matrix material subsequently encapsulates both the fibres and connecting elements together, creating a secure connection while preserving fibre integrity.
2Device complexity
If metallic connecting elements directly contact the fibre composite material, then the connection is simple, but electrochemical corrosion occurs
Solution Approach 1:
The matrix material serves as an intermediary substance between the metallic connecting elements and the fibre composite material. By encapsulating both components, the matrix creates a protective barrier that prevents direct contact between the metal and the fibre composite, thereby eliminating the risk of electrochemical corrosion while maintaining a relatively simple connection structure.
3Weight of moving object
If the ring beam is made of fibre composite material, then weight is reduced, but connection reliability is compromised
Solution Approach 1:
The metallic connecting elements are positioned in the unconsolidated fibre-reinforcing structure before matrix consolidation, allowing the fibres to naturally arrange around the connectors without damage. This preserves the lightweight fibre composite properties while ensuring reliable mechanical connection through proper fibre orientation and matrix encapsulation.
Solution Approach 2:
The matrix material acts as an intermediary that bonds the metallic connecting elements to the fibre composite structure. This intermediary layer transfers loads effectively between the metal connectors and the fibre reinforcement, maintaining connection reliability while preserving the lightweight characteristics of the fibre composite ring beam.
Data Source
AI summary
The invention relates to a method for connecting a connection piece to a U-shaped ring anchor for a head module for rail vehicles, the head module consisting predominantly of fiber-reinforced plastic material and having an outer shell and the ring anchor consisting of fiber-reinforced plastic material and being arranged in the roof region of the outer shell as a stiffening means. According to the method, connecting elements are fed through the dry or matrix-material-impregnated, unconsolidated fiber reinforcement structure of the ring anchor.