Foamed Composite Hollow Structure With Tensioned Gap Reinforcement
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Solution Overview
Problem
Existing composite components with foamed inserts in hollow structures face challenges in maintaining a consistent gap during cataphoretic painting, which affects corrosion stability and energy absorption performance.
Innovation Solution
A composite component with a tension-active reinforcing structure connected to both the foamed component and the hollow structure, forming a continuous gap without the need for additional spacing elements, enhancing energy absorption and simplifying fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacer points or adhesive pads are used to maintain the gap between the foamed component and the hollow structure, then the gap is maintained during cataphoretic painting, but the device complexity increases due to additional spacing elements
Solution Approach 1:
The patent combines the gap-maintaining function with the reinforcing structure by integrating the reinforcing structure directly into the foamed component. The reinforcing structure serves dual purposes: providing mechanical reinforcement and maintaining the gap between the foamed component and hollow structure, thereby eliminating the need for separate spacer points or adhesive pads.
Solution Approach 2:
The reinforcing structure is designed to perform multiple functions simultaneously: it reinforces the foamed component mechanically and maintains the required gap during cataphoretic painting. This multi-functional design reduces the number of separate components needed in the system.
2Reliability
If a gap is maintained between the foamed component and hollow structure during cataphoretic painting, then corrosion stability is improved, but the energy absorption capability may be reduced due to reduced contact area
Solution Approach 1:
The patent merges the gap-maintaining function with the reinforcing structure, allowing the gap to be preserved for corrosion protection while the reinforcing structure compensates for the reduced contact area by providing additional mechanical strength and energy absorption capability.
Solution Approach 2:
The patent uses a composite structure combining the foamed component with an integrated reinforcing structure. This composite design maintains the gap for corrosion protection while the reinforcing structure provides the necessary mechanical properties for energy absorption, achieving both goals simultaneously.
3Strength
If the foamed component is directly inserted into the hollow structure without a gap, then energy absorption is maximized, but corrosion protection is compromised due to coating liquid inability to reach all surfaces
Solution Approach 1:
The patent combines the gap-maintaining function with the reinforcing structure, allowing the gap to be preserved for corrosion protection while the reinforcing structure compensates for the reduced contact area by providing additional mechanical strength and energy absorption capability.
4Manufacturing precision
If multiple spacing elements are used to maintain the gap, then the gap consistency is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The patent combines the gap-maintaining function with the reinforcing structure by integrating the reinforcing structure directly into the foamed component. The reinforcing structure serves dual purposes: providing mechanical reinforcement and maintaining the gap between the foamed component and hollow structure, thereby eliminating the need for separate spacer points or adhesive pads.
Solution Approach 2:
The reinforcing structure is designed to perform multiple functions simultaneously: it reinforces the foamed component mechanically and maintains the required gap during cataphoretic painting. This multi-functional design reduces the number of separate components needed in the system.
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 solution improves corrosion protection and energy absorption by ensuring a clean flow of anticorrosive liquids and increasing the composite's ability to withstand mechanical loads.
Implementation Method 1
a tension-active reinforcing structure is connected to the foamed component and end-portions of the tension-active reinforcing structure are connected to the hollow structure in such a way that the foamed component does not contact the hollow structure and the gap is formed between the hollow structure and the foamed component
Implementation Method 2
the vehicle chassis is treated by cataphoretic painting. During cataphoretic painting, the vehicle chassis is immersed into an immersion bath containing a coating liquid with the anticorrosive
Data Source
AI summary
The invention relates to a composite component (1) comprising a hollow structure (3) and a foamed component (5) which is inserted in the hollow structure (3), a gap (15) being formed between the hollow structure (3) and the foamed component (5), wherein a tension-active reinforcing structure (17) is connected to the foamed component (5) and end-portions (19) of the tension-active reinforcing structure (17) are connected to the hollow structure (3) in such a way that the foamed component (5) does not contact the hollow structure (3) and the gap (15) is formed between the hollow structure (3) and the foamed component (5). The invention further relates to a process for producing the composite component.