Hybrid Wheel Carrier with Perforated Steel Insert
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Solution Overview
Problem
Chassis parts made from fiber-reinforced plastic composites without a metallic carrier element often lack sufficient strength to withstand impact loads, leading to brittle fractures and potential safety risks in motor vehicles.
Innovation Solution
A chassis part comprising a fiber-reinforced plastic composite with a metallic carrier element formed from a metal sheet having numerous openings, where the composite is composed of two components: one with continuous fibers for directional strength and another with discontinuous fibers for multidirectional force absorption, integrated with a perforated metal sheet for enhanced stability and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a chassis part is made from fiber-reinforced plastic composite without a metallic carrier element, then the weight is reduced, but the strength and impact resistance are insufficient leading to brittle fracture
Solution Approach 1:
The patent applies composite materials by combining fiber-reinforced plastic composite with a metallic carrier element (steel insert) to create a hybrid structure. The steel insert provides the necessary strength and ductility to prevent brittle fracture, while the fiber-reinforced plastic maintains weight reduction benefits. This composite approach resolves the contradiction by integrating two material systems with complementary properties.
Solution Approach 2:
The metallic carrier element is strategically positioned within the fiber-reinforced plastic composite at critical locations where impact loads and forces are expected. The steel insert is not uniformly distributed but placed specifically to provide local reinforcement where needed, maintaining overall weight efficiency while ensuring strength at critical points.
2Ease of manufacture
If a chassis part is made from fiber-reinforced plastic composite without a metallic carrier element, then the production cost is reduced, but the reliability under impact loads deteriorates
Solution Approach 1:
The metallic carrier element is pre-formed and positioned within the mold cavity before the fiber-reinforced plastic composite is applied. This preliminary placement ensures proper positioning and integration of the steel insert, allowing for a streamlined production process that does not require complex post-assembly operations, thereby maintaining cost-effectiveness while ensuring reliable integration.
3Strength
If continuous fibers are used in fiber-reinforced plastic composite, then directional strength is improved, but multidirectional force absorption is reduced
Solution Approach 1:
The patent employs continuous fibers oriented in specific directions to provide high directional strength where required by the structural design and load paths. The metallic carrier element complements this by providing multidirectional force absorption capability, creating a hybrid system where each material type addresses its strength profile optimally.
Data Source
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AI summary
The invention relates to a chassis component of a motor vehicle, in particular a wheel carrier, comprising a fiber-reinforced plastic composite with a metallic support element (4), wherein the support element (4) is formed from a metal sheet having a plurality of openings (28).To achieve high component strength in such a chassis component while saving material weight and enabling cost-effective production, the invention provides that the fiber-reinforced plastic composite is composed of at least two different components (2, 6), wherein a first component (2) of the plastic composite is arranged on a first side of the support element (4) and wherein a second component (6) of the plastic composite is arranged on a side of the support element (4) opposite the first side, wherein the first component (2) is made of fiber-reinforced plastic with continuous fibers (74), and wherein the second component (6) is made of fiber-reinforced plastic with discontinuous fibers (80). The invention also relates to a method for manufacturing a chassis component, in particular a wheel carrier.