Layered Fiber-Reinforced Insert for Corrosion-Resistant Joints
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Solution Overview
Problem
Fiber-reinforced plastic components in motor vehicles are prone to galvanic corrosion when joined with metal parts, compromising the strength of the joint, and existing solutions do not adequately address the risk of corrosion and energy absorption under opposing forces.
Innovation Solution
A layered insert made of fiber-reinforced materials with a nonlinear profile is positioned between the fiber-reinforced plastic component and the metal component, reducing fiber exposure and enhancing energy absorption by varying fiber orientations across layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber-reinforced plastic components are joined with metal parts, then structural strength and durability are improved, but galvanic corrosion occurs compromising joint strength
Solution Approach 1:
The patent introduces an insert as an intermediary component positioned between the fiber-reinforced plastic component and the metal component. This insert acts as a mediator that prevents direct contact between the fiber-reinforced plastic and metal, thereby eliminating the galvanic corrosion pathway while maintaining the structural strength of the joint.
Solution Approach 2:
The patent divides the joint structure into three separate segments: the fiber-reinforced plastic component, the insert, and the metal component. This segmentation physically separates materials that would otherwise be in direct contact, preventing galvanic corrosion while preserving the load-bearing capacity of each component.
2Reliability
If existing corrosion protection solutions are used, then corrosion risk is reduced, but energy absorption capability under opposing forces is insufficient
Solution Approach 1:
The patent employs the insert as a composite material structure that combines corrosion resistance with high energy absorption capabilities. The insert is designed to withstand opposing forces and absorb impact energy while maintaining its protective function against galvanic corrosion, thereby simultaneously addressing both corrosion protection and energy absorption requirements.
3Ease of manufacture
If direct joining of fiber-reinforced plastic and metal is performed, then manufacturing simplicity is maintained, but fiber exposure to metal causes galvanic corrosion
Solution Approach 1:
The insert serves as a mediator that can be integrated into the manufacturing process without significantly complicating production. It prevents fiber exposure to metal during assembly and operation, eliminating galvanic corrosion while maintaining ease of manufacture through standardized insertion procedures.
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
The insert significantly reduces the risk of corrosion and enhances the structural integrity of the joint by minimizing fiber exposure to metal, while its energy-absorbing properties prevent separation under opposing forces.
Implementation Method 1
Fiber-reinforced plastic is made of a polymer matrix reinforced with fibers... When fibers in a fiber-reinforced material are exposed to metal, the fibers can cause galvanic corrosion in the metal
Implementation Method 2
One of a boundary between the inner and middle layers and a boundary between the middle and outer layers has a nonlinear profile in a direction parallel to the axis A... the insert may also provide additional energy absorption when the first and second components are subjected to opposing forces
Data Source
AI summary
A joined structure includes a first component, a second component, and an insert. The first component is formed of a fiber-reinforced material and has a hole defining an axis. The second component is adjacent the first component and has a hole aligned with the hole of the first component. The insert is positioned in the hole of the first component. The insert includes an inner layer having a tubular shape about the axis, a middle layer concentrically adjacent to the inner layer about the axis, and an outer layer concentrically adjacent to the middle layer about the axis. The layers are formed of fiber-reinforced materials. One of a boundary between the inner and middle layers and a boundary between the middle and outer layers has a nonlinear profile in a direction parallel to the axis.