Fiber-Reinforced Plastic Frame Bracket for Vehicle Body
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Solution Overview
Problem
Existing motor vehicle frame structures face challenges in improving the connection to other components while maintaining weight savings and structural integrity, particularly in using fiber-reinforced plastic components.
Innovation Solution
Incorporating a console made of fiber-reinforced plastic with an integrated bracket on the profile components, which serves as a support element and force introduction point, and using a pressing tool process to manufacture the bracket, ensuring the profile components are hollow and reinforced with short fibers, and using a plastic foam closure element to prevent material penetration during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced plastic profile components are used to achieve weight savings, then the weight of the frame structure is reduced, but the connection capability to other components deteriorates
Solution Approach 1:
The profile component is segmented into the main profile body and an integrated bracket portion. The bracket is formed as a separate functional element within the mold cavity, allowing it to be molded onto the profile component while maintaining distinct geometric features for connection purposes.
Solution Approach 2:
The bracket is merged with the profile component through integral molding, creating a unified fiber-reinforced plastic structure. The bracket and profile share the same material matrix and reinforcing fibers, ensuring structural integrity while providing enhanced connection capability without adding separate metal components.
2Adaptability or versatility
If a bracket is added to the profile component to improve connection capability, then the connection capability is improved, but the device complexity increases
Solution Approach 1:
The bracket is combined with the profile component in a single integral structure molded from fiber-reinforced plastic. This merging eliminates the need for separate bracket components, fasteners, and assembly steps, thereby improving connection capability while maintaining simple device architecture.
Solution Approach 2:
The bracket serves multiple functions: it provides connection surfaces for attaching other components, acts as a reinforcement element for the profile component, and serves as a mounting point for various vehicle body attachments. This multi-functionality improves connection capability without proportionally increasing structural complexity.
3Strength
If the bracket is molded onto the profile component using fiber-containing plastic compound, then the structural integrity is maintained, but the material penetration into the profile component occurs
Solution Approach 1:
The hollow interior of the profile component is extracted or removed from the molding process by introducing a closure element. This closure element occupies the profile's internal cavity during molding, preventing the fiber-containing plastic compound from penetrating into the profile component while allowing the bracket to be molded onto the external surface.
Solution Approach 2:
The closure element acts as an intermediary between the molding process and the profile component's hollow interior. It mediates the molding process by providing a barrier that prevents material penetration while allowing the bracket to form integrally on the profile's outer surface with proper structural integrity.
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 solution enhances the connection capabilities of the frame structure, maintains structural integrity and weight savings, and allows for local reinforcement without damaging the reinforcing fibers, while enabling the production of a bracket with final geometry without post-processing, thus improving the overall strength and crash stability of the vehicle body.
Implementation Method 1
The console is made of a fiber-reinforced plastic. The fiber-reinforced plastic material can be injection-molded or pressed onto the relevant profile component
Implementation Method 2
performing a pressing operation with the addition of fiber-containing and in particular short-fiber-containing plastic compound to produce the console
Implementation Method 3
The open profile end is first closed by a closing element, which then prevents the fiber-containing plastic compound from penetrating into the hollow profile component during the pressing process
Data Source
Figure 1~2
Figure 3a~3c
AI summary
The invention relates to a frame structure (100) for a motor vehicle body, comprising at least two profile components (120, 130, 140, 150) and a connecting node (160) that connects the profile components (120, 130, 140, 150) to one another. At least one of the profile components (120, 130) has at least one bracket (170, 180) made of fiber-reinforced plastic (K) to which other components can be attached or supported. The invention further relates to a motor vehicle body with such a frame structure (100) and a method for manufacturing a bracket (170, 180).