Polymeric Composite Crankshaft Assemblies for Weight Reduction
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Solution Overview
Problem
Traditional metal engine components in vehicles are heavy, leading to reduced fuel economy and performance due to their high weight, and lightweight alternatives like aluminum and magnesium alloys face issues with thermal expansion and strength degradation at high temperatures, necessitating the development of durable and efficient lightweight crankshaft assemblies.
Innovation Solution
The use of polymeric composite materials, comprising a polymer and reinforcing fibers such as carbon or glass fibers, in crankshaft assemblies to reduce weight while maintaining structural integrity and durability, with manufacturing methods involving resin infusion and solidification within molds to form polymeric composite crankpins and webs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal components are used in engine assemblies, then strength and durability are improved, but weight increases reducing fuel economy
Solution Approach 1:
The patent applies composite materials by combining polymer matrices with reinforcing fibers (carbon, glass, aramid, or metallic fibers) to create crankshaft components that achieve both lightweight properties and high strength. The composite structure allows the material to maintain structural integrity while significantly reducing weight compared to traditional metal components.
2Weight of moving object
If lightweight metal components are used to reduce weight, then fuel economy is improved, but thermal expansion issues cause component separation
Solution Approach 1:
The patent uses polymeric composite materials with reinforcing fibers that provide low thermal expansion characteristics. This composite structure enables the crankshaft components to maintain dimensional stability under thermal loading, preventing component separation while keeping the overall weight reduced for improved fuel economy.
3Weight of moving object
If lightweight reinforced composite materials are used, then weight is reduced, but tensile strength diminishes
Solution Approach 1:
The patent employs reinforcing fibers embedded in a polymer matrix to create a composite material that maintains high tensile strength despite reduced weight. The fiber reinforcement provides the necessary mechanical strength while the polymer matrix binds the fibers together, achieving an optimal balance between weight reduction and tensile strength retention.
4Use of energy by moving object
If lightweight materials are used in crankshaft assemblies, then fuel efficiency is improved, but durability under high temperature degrades
Solution Approach 1:
The patent uses polymeric composite materials with high-temperature resistant reinforcing fibers that maintain structural integrity and durability under the high-temperature conditions of engine operation. This composite structure enables weight reduction for improved fuel efficiency while preserving the necessary durability for reliable engine performance.
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 polymeric composite crankshaft assemblies achieve weight reduction, improved thermal stability, and enhanced durability, leading to increased fuel efficiency and performance by mitigating thermal expansion issues and maintaining structural integrity.
Implementation Method 1
introducing a resin into the mold, and solidifying the resin to produce a first polymeric composite crankpin
Data Source
AI summary
Crankshaft assemblies for vehicle assemblies, such as engine assemblies, and methods of manufacturing crankshaft assemblies are provided. The crankshaft assembly includes a first crankpin disposed between a first pair of webs and at least a first main bearing journal connected to the first pair of webs, wherein at least one of the first crankpin, the first pair of webs or the first main bearing journal is a polymeric composite including a polymer and a plurality of reinforcing fibers.