Hollow Profile Component Joining via Form-Fitting Undercuts
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Solution Overview
Problem
The existing methods for producing hollow-profile components, such as wheel rims, from fiber composite materials require significant manual effort and result in mechanical weaknesses due to limited fiber alignment options, and the joining process of prefabricated components is technically demanding and prone to weak points under high loads.
Innovation Solution
The method involves prefabricating components with a form-fitting connection by dimensioning the second component to create a radial projection or depression on the mold, allowing components to be assembled during the prefabrication phase, which eliminates the need for a separate joining process and enhances mechanical strength through a non-detachable undercut connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If components are prefabricated separately and then joined, then manufacturing flexibility and material optimization are improved, but the joining process creates critical weak points and requires considerable technical effort
Solution Approach 1:
The wheel rim is divided into multiple components (wheel disc, rim base, rim flanges) that can be prefabricated separately with optimized fiber structures for their specific load conditions, then joined together. This segmentation allows manufacturing flexibility while the invention addresses the connection weakness through specific joining techniques.
Solution Approach 2:
The invention merges the joining process with the prefabrication phase by creating form-fitting connections where components are dimensioned to interlock during molding. This combining eliminates separate joining operations, reducing technical effort while maintaining connection strength through geometric interlocking.
2Device complexity
If a monolithic production method is used, then manufacturing process simplicity is improved, but manual effort increases and fiber alignment options are limited reducing mechanical strength
Solution Approach 1:
The monolithic structure is segmented into multiple components that can be manufactured separately with optimized fiber orientations for each component's specific stress conditions, thereby improving mechanical strength while maintaining relatively simple manufacturing processes.
Solution Approach 2:
Each component is designed with locally optimized fiber structures tailored to the specific load requirements of different regions (wheel disc vs. rim base vs. rim flanges), achieving superior mechanical strength compared to uniform monolithic construction.
3Reliability
If components are connected with form-fitting undercut connections, then mechanical strength and connection reliability are improved, but manufacturing precision requirements increase
Solution Approach 1:
The form-fitting connections are designed into the mold geometry itself, with undercuts and interlocking features pre-formed in the molding tools. This preliminary action ensures that components achieve precise dimensional fit during the prefabrication phase, reducing the need for post-processing while maintaining high connection reliability.
Data Source
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AI summary
The invention relates to a method for producing a hollow-profile-like component from a first, hollow-profile component (4) made of fiber composite material and a second component (8), wherein, for the prefabrication of the first component (4), a preform (4) of this component (4) is formed as an intermediate product, which is formed into a fiber structure corresponding to the component geometry of the first component (4) by depositing a fiber material (5) on a forming tool (2) that maps the contour (3) of the first, hollow-profile component (4) and is subsequently solidified by consolidation.During the formation of the preform (4) of the first component, the preform (4) is positively connected to the second component (8), the second component (8) being dimensioned and enclosed by the multi-part forming tool (2, 6, 7) such that when the fiber material (5) is deposited onto the forming tool (2, 6, 7), which forms the contour (3) of the first component (4), and onto the second component (8), a contour of the second component (8) that is set off from the circumferential contour of the forming tool (2, 6, 7) is at least partially enclosed (Fig. 1).