Fibre Composite Wheel Rim Co-Curing Diffusion
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Solution Overview
Problem
Existing methods for producing fibre composite bodies, such as wheel rims, require complex and expensive surface activation processes to create a boundary layer between insert parts and preform structures, leading to potential detachment and the need for costly post-processing to achieve homogeneous fibre volume content and mechanical stability.
Innovation Solution
A method involving a moulding process where a fibrous raw material and binder are introduced into a mould, with energy input to form a mould element open to diffusion, which is then joined with a preform structure and infiltrated with resin, eliminating the need for a boundary layer through co-curing and achieving micro-interlocking, thus enhancing mechanical properties and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface activation is performed to create a boundary layer between insert part and preform structure, then mechanical stability is improved, but device complexity and production cost increase
Solution Approach 1:
The invention eliminates the boundary layer (material notch) by directly infiltrating the insert part with resin during the moulding process, removing the need for surface activation processes while maintaining mechanical stability
Solution Approach 2:
The insert part production and preform structure infiltration are merged into a single co-curing process, where both components are cured simultaneously in one moulding cycle, eliminating separate surface treatment steps
2Reliability
If surface activation is performed to prevent detachment, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The insert part is pre-formed with a diffusion-open structure before infiltration, allowing resin to penetrate directly into the insert part material without requiring subsequent surface activation treatments
Solution Approach 2:
The invention converts the potential harm of a boundary layer (material notch causing detachment) into a benefit by using the same boundary region as a diffusion-open structure that actively promotes resin penetration and bonding
3Reliability
If complex cleaning processes are performed to prevent detachment, then reliability is improved, but loss of time increases
Solution Approach 1:
The diffusion-open structure is built into the insert part during its formation, enabling resin infiltration to occur during the main moulding process without requiring subsequent cleaning or treatment operations
Solution Approach 2:
The resin infiltration and curing process continues uninterrupted from the insert part formation through to final consolidation, eliminating separate cleaning and treatment stages
4Strength
If insert parts are used to stabilise regions, then strength is improved, but device complexity increases
Solution Approach 1:
The insert part and preform structure are merged into a single integrated component through co-curing, where both are formed and bonded simultaneously in one moulding process, reducing structural and manufacturing complexity
Solution Approach 2:
The insert part is formed with a diffusion-open (porous) structure that facilitates resin penetration and creates mechanical interlocking with the preform structure, achieving bonding without additional surface treatments
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 method results in a fibre composite body with increased mechanical stability and weight savings, eliminating the need for post-processing and reducing production costs by integrating the mould element as an insert part within the fibre composite body, achieving net shape production and improved fibre volume fraction control.
Implementation Method 1
a mould element which is open to diffusion is formed
Implementation Method 2
supplying a resin which infiltrates, i.e. flows around, both the mould element and the preform structure
Implementation Method 3
The binder is activated by means of an application of pressure and/or temperature on the mould
Implementation Method 4
a mould element which is open to diffusion is formed as a result of this preforming
Data Source
AI summary
The invention relates to a method for producing a fibre composite body (2), in particular at least a part of a wheel, comprising the following steps: providing a mould (4) having at least one female mould part (6) and one male mould part, introducing a fibrous raw material (8) and a binder (10) into the female mould part (6), activating the binder (10) by an energy input (p, T) into the mould (4) to form a mould element (12) which is open to diffusion, joining together the mould element (12) which is open to diffusion and a preform structure (14), supplying a resin, so that the resin infiltrates at least partially into the mould element (12) which is open to diffusion and into the preform structure (14), and curing the resin, so that in this way the fibre composite body (2) is formed without a boundary layer.