Hybrid Component Manufacturing Localized Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing motor vehicle hybrid components are energy-intensive due to the need to heat the entire base body, leading to high energy costs and inefficient manufacturing processes.
Innovation Solution
A method involving a three-dimensionally shaped metallic base body and a reinforcement pad made of fiber composite material, where the fiber material layers are pre-impregnated with resin, cut to form a blank, heated on a preform, and molded onto the base body using a pressing process, with targeted heating of the blank to reduce energy input and enhance adhesive connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire base body is heated to form the hybrid component, then the fiber composite material can be properly bonded to the metallic base body, but the energy consumption increases significantly
Solution Approach 1:
The heating process is segmented from a global heating of the entire base body to a localized heating only at the bonding area where the fiber composite material contacts the metallic base body. This segmentation allows the bonding process to occur with significantly reduced energy input while maintaining adequate bonding quality at the interface.
Solution Approach 2:
Instead of uniformly heating the entire base body, the heating is applied locally only at the specific bonding zone. This local quality approach ensures that the fiber composite material receives sufficient heat for proper bonding to the metallic base body, while the rest of the base body remains unheated, thereby reducing overall energy consumption.
2Reliability
If conventional heating methods are used to produce hybrid components, then complete bonding can be achieved, but the production cost increases due to high energy costs
Solution Approach 1:
The heating process is segmented to affect only the bonding interface area rather than the entire base body. This segmentation maintains complete bonding at the critical interface while reducing the total energy input required, thereby lowering production costs associated with energy consumption.
Solution Approach 2:
The heating is applied with local quality, concentrating thermal energy only where the fiber composite material meets the metallic base body. This localized approach ensures complete bonding where needed while avoiding unnecessary heating of other areas, thus reducing overall production costs.
3Manufacturing precision
If the base body is heated to high temperature for forming, then the fiber composite material achieves proper curing, but the manufacturing process becomes less efficient
Solution Approach 1:
The thermal processing is segmented to apply heat only at the bonding interface rather than throughout the entire base body. This segmentation achieves adequate curing of the fiber composite material at the bonding zone while significantly reducing the total thermal energy required, thereby improving manufacturing efficiency without compromising curing quality.
Solution Approach 2:
The heating process is applied with local quality, concentrating thermal energy precisely at the bonding interface where curing is needed. This localized heating achieves proper curing of the fiber composite material while minimizing energy consumption and processing time, thus enhancing overall manufacturing 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 reduces energy consumption, allows for more cost-effective production, and results in hybrid components with improved accuracy and crash performance compared to conventional methods.
Implementation Method 1
the blank being given a three-dimensional preform by the action of heat
Implementation Method 2
curing of the blank
Data Source
Figure 1~2
Figure 3a~3e
AI summary
The present invention relates to a method for manufacturing a vehicle hybrid component and to a vehicle hybrid component manufactured according to the invention. In the method according to the invention, a reinforcing patch (10) is molded into a base body (1), wherein the reinforcing patch (10) is made of fiber-reinforced composite material. According to the invention, only the reinforcing patch (10) is heated, so that a low energy input is made during the manufacturing process. This reduces production costs and simultaneously increases production quality.