Fiber Composite Hybrid Bonding via Inductive Pre-Heating
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Solution Overview
Problem
The production of fiber composite hybrid materials in aerospace and automotive industries is hindered by the complexity and costliness of the multi-stage autoclave process, particularly due to the need for positioning pins and multiple vacuum build-ups, which are time-consuming and risk-prone.
Innovation Solution
A method involving a fiber composite hybrid material with alternating fiber and metal layers, where an uncured adhesive layer is pre-tempered between components to increase surface adhesion without full curing, allowing for co-bonding of the adhesive and matrix materials in a single process step, eliminating the need for fixing pins and reducing process complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If positioning pins are used to attach stiffening elements to the skin field, then the components can be securely positioned during bonding, but the process becomes complex and time-consuming with multiple vacuum build-ups required
Solution Approach 1:
The invention removes positioning pins from the bonding process entirely. Instead of using mechanical pins to hold components in place, the method relies on adhesive bonding alone, eliminating the need for pin insertion, positioning, and removal steps that complicate the process
Solution Approach 2:
The components are pre-positioned and the adhesive is applied before curing, allowing the adhesive itself to provide positioning stability during the bonding process, eliminating the need for separate positioning aids
2Manufacturing precision
If multiple vacuum build-ups are performed for skin field curing and stringer integration, then each bonding stage can be properly executed, but the production time increases significantly
Solution Approach 1:
The invention combines skin field curing and stringer integration into a single bonding operation. By applying adhesive to the skin field and simultaneously integrating stiffening elements in one step, only one vacuum build-up is required, halving the number of vacuum cycles compared to the traditional multi-stage process
Solution Approach 2:
The bonding process continues uninterrupted with a single vacuum hold, allowing the adhesive to cure while components remain in place without requiring repeated vacuum cycles for different bonding stages
3Manufacturing precision
If positioning pins are integrated during shell fabrication and then removed, then components can be accurately positioned, but the process becomes more complex and the risk of vacuum film damage increases
Solution Approach 1:
The invention eliminates positioning pins from the process entirely, removing the source of potential vacuum film damage. Without sharp pins being inserted and removed, the risk of puncturing or damaging the vacuum film is completely eliminated
Solution Approach 2:
The adhesive acts as an intermediary that provides both positioning and bonding functions, replacing the mechanical positioning pins and eliminating the need for separate positioning and bonding operations
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 process by enabling the integration of stiffening elements without pins, reducing process time and cost, and ensuring a single vacuum build-up, while ensuring secure bonding of components.
Implementation Method 1
The adhesive material is heated by means of inductive heating in order to fix the two fiber composite components together
Implementation Method 2
an alternating electromagnetic field is radiated into the first component in at least one partial area for the inductive heating of one or more metal layers of the fiber-reinforced hybrid material
Data Source
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AI summary
A method for manufacturing a component (100) from at least two components (110, 120) to be bonded together, comprising the steps of: - providing a first component (110) made of a fiber-reinforced hybrid material formed from alternating fiber and metal layers (112, 114) in which the fiber layers (112) comprise a fiber material and a matrix material of a fiber-reinforced composite material, - providing at least one second component (120) which is or is arranged on the first component (110) by means of an uncured adhesive layer (130) between the components (110, 120), - tempering the uncured adhesive layer (130) in at least one sub-area (160) by tempering one or more metal layers (114) of the fiber-reinforced hybrid material of the first component (110) in at least this sub-area (160), such thatthat the adhesive layer (130) in this partial area (160) achieves a higher surface adhesion than the uncured adhesive layer (130), without fully curing, in order to fix the second component (120) to the first component (110), and - insertion of the fixed components (110, 120) into an oven (150) and tempering of the fixed components (110, 120) to fully cure the adhesive layer (130) between the first component (110) and the second component (120).