Four-Point Link with Foam Core and Positive Engagement
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Solution Overview
Problem
Existing four-point links made from fiber reinforced plastics composite materials face challenges in large-series production due to high centrifugal forces during the winding process, which increases production costs and makes the fixing of load-introducing elements unreliable.
Innovation Solution
A four-point link design featuring a core element with a foam core and load-introducing elements connected by positive engagement, where additional windings made of fiber reinforced plastics composite material wrap around the load-introducing elements to connect them to the main laminate, allowing for the transmission of compressive forces and facilitating high-speed winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the winding process is performed at high speed, then productivity is improved, but high centrifugal forces occur which make the fixing of load-introducing elements unreliable
Solution Approach 1:
The load-introducing elements are pre-fixed to the foam core before the winding process begins. This preliminary fixation ensures that the elements are securely in place before high-speed winding starts, preventing them from moving or becoming loose under centrifugal forces during the winding process.
Solution Approach 2:
The foam core serves as an intermediary component that provides a stable base for fixing the load-introducing elements. The foam core's cellular structure allows for reliable mechanical attachment of the elements, distributing the centrifugal forces evenly and maintaining secure fixation during high-speed winding operations.
2Reliability
If the winding process proceeds at slow speed, then the fixing of load-introducing elements is reliable, but productivity decreases
Solution Approach 1:
The load-introducing elements are pre-fixed to the foam core before the winding process begins. This preliminary fixation ensures that the elements are securely in place before high-speed winding starts, preventing them from moving or becoming loose under centrifugal forces during the winding process.
3Weight of moving object
If the four-point link is made integrally or in shell construction, then weight is reduced, but suitability for large-series manufacture is compromised
Solution Approach 1:
The four-point link is divided into separate components: the foam core with pre-fixed load-introducing elements, and the main laminate that is wound around them. This segmentation allows each component to be prepared separately and then assembled through the winding process, making the manufacturing process more suitable for large-series production while maintaining the lightweight characteristics of composite materials.
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 design enables reliable force transmission during load events, reduces production costs, and allows for efficient large-series production by eliminating the need for slow winding speeds, while maintaining a lightweight structure.
Implementation Method 1
The four load-introducing elements (4) are connected by positive engagement to the foam core (5)
Implementation Method 2
Compressive forces can be introduced into the main laminate (3) by means of every additional winding (6)
Data Source
AI summary
A four-point link for a vehicle includes a core element and a main laminate comprising a fiber reinforced plastics composite material, which wraps around the core element. The core element comprises four load-introducing elements and a foam core, and the four load-introducing elements (4) are connected by positive engagement to the foam core (5). The four-point link has four additional windings, wherein a respective additional winding wraps around a first, second, third and fourth load-introducing element and operatively connects a respective one of the latter to the main laminate. Compressive forces can be introduced into the main laminate (3) by means of every additional winding (6).