Fiber-Reinforced Plastic Vehicle Component with Embedded Metal
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Solution Overview
Problem
Vehicle structural components made from fiber-reinforced plastic lack effective connection methods to the vehicle structure, as conventional welding techniques are not applicable, necessitating a solution for achieving high rigidity, strength, and lightweight design while enabling connection to the body structure.
Innovation Solution
A vehicle structural component comprising fiber-reinforced plastics inserts and an injection-molded rib structure connected to metallic elements, allowing for hot connection techniques like welding, with the metallic elements integrated for energy absorption and attachment of movable parts, and the rib structure providing lightweight design and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced plastic is used for vehicle structural components, then weight is reduced, but connection capability to the vehicle structure is lost
Solution Approach 1:
The patent applies composite materials by combining fiber-reinforced plastic inserts with metallic elements in a single structural component. The fiber-reinforced plastic provides lightweight construction while the metallic elements provide connection capability through welding and other conventional joining methods, thus resolving the contradiction between weight reduction and connection capability.
Solution Approach 2:
The patent merges different materials (fiber-reinforced plastic and metal) into a single integrated component. The metallic elements are embedded within or attached to the fiber-reinforced plastic structure, allowing the component to simultaneously achieve lightweight properties and conventional connection methods, eliminating the need for separate connection components.
2Ease of manufacture
If metallic elements are integrated into fiber-reinforced plastic structure, then connection capability is restored, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning metallic elements within the mold cavity before injection of the fiber-reinforced plastic material. This allows the metallic elements to be precisely located and securely embedded in the final structure without requiring post-manufacturing assembly operations, thereby reducing overall manufacturing complexity despite the multi-material nature of the component.
3Strength
If fiber-reinforced plastics inserts are used, then rigidity is achieved, but connection to vehicle structure becomes difficult
Solution Approach 1:
The patent applies local quality by concentrating metallic elements at specific locations within the fiber-reinforced plastic structure where connection capability is most needed. The metallic elements are strategically positioned at attachment points and connection zones, while the bulk of the structure maintains the lightweight fiber-reinforced plastic material, thus achieving both rigidity and connectability without compromising either property.
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 achieves high local ductility for energy absorption, enables punctiform force introduction, and allows for reliable connection to the vehicle structure, ensuring high rigidity and lightweight construction, facilitating large-series production.
Implementation Method 1
the at least one metallic element can be connected to the injection-molded rib structure by an integrally bonded connection, frictional connection and/or form-fitting connection, in particular by adhesive bonding
Implementation Method 2
by means of the integrated metallic elements, high local ductility for absorbing energy in the event of high structural loading is achieved
Implementation Method 3
the reinforcing webs are injection molded here on fiber-reinforced plastics inserts. Furthermore, the reinforcing webs are connected to one another via the connecting point and permit a lattice-like distribution of force
Data Source
AI summary
A vehicle structural component includes at least one first and at least one second fiber-reinforced plastics insert, an injection-molded rib structure, where the injection-molded rib structure connects the plastic inserts and is injection-molded onto the plastic inserts, and at least one metal element which forms an attachment region of the vehicle structural component.