Hybrid Steel-Composite Forming With Undercut Bonding
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Solution Overview
Problem
The existing methods for bonding composite materials to steel plates in vehicle components are limited by low productivity and high costs, due to the requirement of multiple processes and difficulty in expanding the application of composite materials, which restricts the weight reduction and performance enhancement of vehicle bodies.
Innovation Solution
A system and method for manufacturing hybrid components that involves heating a steel plate with a xenon beam to 900°C, forming an undercut on its surface, and simultaneously bonding a composite material tape using a second thermal supplier, which increases the bonded surface area and mechanical interlocking, thereby improving the coupling force between the steel plate and the composite material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thermal pressurization method is used to bond composite material to steel plate, then bonding strength is improved, but the number of processes increases to 12 or more steps, resulting in very low productivity
Solution Approach 1:
The patent combines multiple separate processes (heating, undercut formation, composite application, pressurization) into a single integrated rolling operation. The rolling roll performs all functions simultaneously in one pass, reducing the process count from 12+ steps to essentially one continuous operation, thereby dramatically improving productivity while maintaining bonding strength.
Solution Approach 2:
The rolling roll is designed as a multi-functional device that simultaneously heats the steel plate, forms the undercut pattern, applies the composite material, and pressurizes the bond interface. This universal tool eliminates the need for separate equipment for each process step, streamlining production and enhancing productivity.
2Weight of moving object
If ultra-high-tensile steel plate is applied to reduce vehicle body weight, then weight reduction is achieved, but there is a limit to further weight reduction while securing rigidity performance
Solution Approach 1:
The patent applies composite material (such as CFRP) in patch form to specific portions of the steel plate component where reinforcement is needed. This creates a hybrid component that combines the high strength-to-weight ratio of composites with the structural integrity of steel, enabling further weight reduction while maintaining or enhancing rigidity performance beyond what ultra-high-tensile steel alone can achieve.
3Weight of moving object
If composite material is applied to reduce vehicle body weight, then weight reduction and specific strength improvement are achieved, but bonding to metal is difficult and expansion to various components is limited
Solution Approach 1:
The patent applies composite material in the form of patches only to specific local areas of the steel plate component where reinforcement is required, rather than attempting to bond large areas or complex geometries. This localized approach simplifies the bonding process, makes the technology easier to manufacture and implement, and allows expansion to various component types while maintaining weight reduction benefits.
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 approach significantly enhances productivity by reducing the manufacturing time to 33 seconds per component and improves the bonding force, allowing for a 20% weight reduction and a 30% increase in bending strength while maintaining the structural integrity of the vehicle body.
Implementation Method 1
a first thermal supplier configured to heat a steel plate... the first thermal supplier uses a xenon beam
Implementation Method 2
a rolling roll for undercut configured to pressurize the steel plate heated by the first thermal supplier, and to form an undercut on one surface of the steel plate
Implementation Method 3
a first molding roll configured to pressurize the steel plate formed with the undercut to mold the steel plate in a shape of a component to be manufactured
Implementation Method 4
a composite material pressurization roll configured to pressurize the steel plate on which the composite material tape is seated
Implementation Method 5
a refrigerant gas circulator configured to supply refrigerant, in which the refrigerant is circulated inside the first molding roll... the steel plate is cooled to 200°C or less within 10 seconds after passing through the first molding roll
Data Source
AI summary
The present disclosure relates to a system for manufacturing a hybrid component including a first thermal supplier configured to heat a steel plate, a rolling roll for undercut configured to pressurize the steel plate heated by the first thermal supplier, and to form an undercut on one surface of the steel plate, a first molding roll configured to pressurize the steel plate formed with the undercut to mold the steel plate in a shape of a component to be manufactured, a composite material feeder configured to supply a composite material tape to be seated on one surface of the steel plate formed with the undercut through the first molding roll, and a composite material pressurization roll configured to pressurize the steel plate on which the composite material tape is seated.