Hollow Profile Joint Using Composite Wrap Without Adhesives
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting hollow profiles in load-bearing structures are complex and often require adhesives, which can introduce thermal stresses and increase manufacturing costs, while also failing to efficiently utilize material properties for enhanced stability.
Innovation Solution
A method involving the use of a moldable and curable sheet-like fiber/plastic composite semi-finished product, which surrounds or partially surrounds the hollow profiles, allowing for a form-fitting connection through crosslinking of thermosetting resin without adhesives, incorporating a foam core for increased stability and reduced fiber content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to connect hollow profiles, then connection strength is improved, but thermal stresses increase and manufacturing costs rise
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the connection process. Instead of using adhesives to bond hollow profiles, the method directly connects profiles through form-fitting joints and mechanical interlocking, thereby removing the source of thermal stress problems associated with adhesive curing.
Solution Approach 2:
The invention introduces a form-fitting joint structure as an intermediary mechanism between hollow profiles. This joint structure provides mechanical interlocking and load transfer without requiring adhesives, thus achieving strong connections while avoiding thermal stress issues.
2Strength
If adhesives are used to connect hollow profiles, then connection strength is improved, but manufacturing costs increase
Solution Approach 1:
The invention removes the adhesive material and its associated application, curing, and quality control processes from the manufacturing workflow. This elimination reduces material costs, processing time, and manufacturing complexity while maintaining connection strength through mechanical joint design.
Solution Approach 2:
The form-fitting joint structure is designed to self-assemble and self-lock without requiring external adhesives or additional fastening components. The profiles themselves provide the connection mechanism through their geometric design, simplifying the manufacturing process.
3Strength
If fiber content is increased to enhance stability, then structural strength is improved, but material usage and cost increase
Solution Approach 1:
The invention applies fiber reinforcement locally only where structural strength is critically needed, rather than uniformly throughout the entire hollow profile. This targeted approach optimizes the strength-to-material-ratio by concentrating fibers in high-stress regions while reducing overall fiber content.
Solution Approach 2:
The invention utilizes composite material structures that combine different materials with complementary properties. By selecting base materials and reinforcement fibers strategically, the design achieves high structural strength without requiring excessive fiber content, optimizing both performance and material efficiency.
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 simplifies the production of stable load-bearing structures by eliminating the need for adhesives, reducing thermal stresses, and enhancing structural integrity while minimizing material usage, thus enabling a lightweight and cost-effective load-bearing structure suitable for motor vehicles.
Implementation Method 1
The resin is initially in a liquid form and crosslinks during pressing, preferably under the action of heat, due to chemical reactions. The crosslinking also is referred to as curing.
Implementation Method 2
The resin is initially in a liquid form and crosslinks during pressing, preferably under the action of heat, due to chemical reactions. The crosslinking also is referred to as curing.
Implementation Method 3
The hollow profiles may comprise a foam core, such as a plastic foam, in particular by a rigid foam. The foam core supports the hollow profile from the inside.
Data Source
AI summary
A method is provided for connecting hollow profiles (1-4) in a joint (10) to produce a load-bearing structure (5). The method includes placing ends of hollow profiles (1-4) in a mold and pressing the ends together with at least one semi-finished product to connect the ends of the hollow profiles to the semi-finished product.