Multi-Shear Preform Overlap for Vehicle Side-Frame Subassembly
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Solution Overview
Problem
In vehicle construction, single-shear preform overlaps in components like the side-frame subassembly lead to weak points due to limited force transmission, which can be exacerbated by the need for a pronounced S curve, compromising the mechanical characteristics of the component.
Innovation Solution
A component arrangement featuring a double- or multi-shear preform overlap, where multiple preforms of one component overlap a preform of another, increasing the contact surface area and enhancing mechanical characteristics, allowing for higher force absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-shear preform overlap is used to connect components, then the device complexity is reduced, but the strength and force transmission capability deteriorate
Solution Approach 1:
The connection is segmented into multiple shear planes by introducing intermediate preforms between the first and second components. This segmentation allows force to be distributed across multiple interfaces, transforming a single weak connection point into multiple load-bearing paths, thereby resolving the contradiction between simple configuration and strong force transmission.
Solution Approach 2:
The overlap configuration transitions from a single-plane (2D) connection to a multi-layered (3D) stacking arrangement. By adding the vertical dimension through intermediate preforms, the connection gains additional shear planes without significantly increasing horizontal complexity, enabling improved strength while maintaining relatively simple device architecture.
2Strength
If the overlap length is increased to counteract weak points, then the strength is improved, but the shape complexity increases due to pronounced S curve requirements
Solution Approach 1:
The total overlap length is segmented into multiple shorter segments separated by intermediate preforms. Each segment maintains a manageable length that avoids pronounced S curves, while the cumulative effect of multiple segments provides the necessary strength through distributed force transmission across several shear planes.
Solution Approach 2:
Instead of extending the overlap length in the horizontal direction (which creates S curves), the solution moves to the vertical dimension by stacking preforms. This allows achieving the required overlap surface area and strength without increasing the horizontal footprint or creating geometric stiffness jumps.
3Force
If multiple preforms are stacked to create multi-shear overlap, then the force absorption capability is improved, but the manufacturing complexity increases
Solution Approach 1:
Multiple preforms are merged into a single integrated laminate structure before resin impregnation. This combining approach allows the multi-shear configuration to be manufactured as one unified component rather than assembling separate parts, significantly reducing manufacturing complexity while maintaining the force absorption benefits of multiple shear planes.
Solution Approach 2:
The preforms are pre-configured and stacked in the correct multi-layer arrangement before the resin transfer molding process. This preliminary action ensures that the complex multi-shear geometry is established upfront, eliminating the need for complex post-assembly operations and simplifying the overall manufacturing process.
Data Source
AI summary
A component arrangement having a first component and a second component is provided. At least one component has a plurality of preforms, wherein the plurality of preforms of the first component overlap a preform of a second component in the connecting region of the two components.