Pultruded Composite Coupling Rod With Overmolded Joint Connection
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Solution Overview
Problem
Existing coupling rods for vehicle chassis lack a lightweight and efficient manufacturing method that maintains high load-bearing capacity and service life while allowing for secure connections to chassis parts.
Innovation Solution
A coupling rod produced from fiber-reinforced plastic using the pultrusion process, with a deformed connecting portion for secure overmolding with a plastic carrier element, and joint elements that can be positioned at various angles, providing a form-fit connection and high load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coupling rod is made from fiber-reinforced plastic by pultrusion with a uniform cross-section, then the manufacturing process is simple and continuous, but the connection security to chassis parts is insufficient
Solution Approach 1:
The patent applies local quality by creating a deformed connecting portion at the end of the rod with a reduced cross-sectional area. This localized deformation creates an interlocking structure that mechanically engages with the overmolded carrier element, providing secure connection at the critical connection point while maintaining the simplicity of the overall pultrusion manufacturing process for the uniform section of the rod.
Solution Approach 2:
The patent uses composite materials by combining fiber-reinforced plastic for the rod body with an overmolded carrier element material for the connection portion. This composite approach allows the fiber-reinforced plastic to provide high strength-to-weight ratio for the main structure, while the overmolded material provides enhanced bonding and mechanical interlocking at the connection point, resolving the contradiction between manufacturing simplicity and connection security.
2Reliability
If the connecting rod has a deformed connecting portion with reduced cross-section, then the connection to carrier element is secure, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by forming the deformed connecting portion during the pultrusion process itself, while the material is still in a formable state. This preliminary shaping creates the interlocking geometry needed for secure connection before the material fully cures, allowing the complex shape to be integrated into the continuous manufacturing process rather than requiring post-processing operations.
Solution Approach 2:
The patent uses parameter changes by temporarily modifying the cross-sectional dimensions of the rod end during the forming process. The deformed connecting portion is created with a reduced cross-sectional area compared to the uniform rod section, and this dimensional parameter change is maintained after curing to create the mechanical interlocking feature. This controlled parameter modification enables secure connection without requiring entirely different manufacturing methods.
3Adaptability or versatility
If joint elements are positioned at various angles, then the adaptability to different chassis configurations is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies dynamics by making the joint element positioning adjustable rather than fixed. The carrier element is designed to accommodate joint elements at various angles, allowing the configuration to be adapted to different chassis requirements. This dynamic adaptability is achieved through the overmolding process that secures the joint element while permitting angular variation, resolving the contradiction between versatility and precision by allowing post-manufacturing adjustment.
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 solution results in a lightweight coupling rod with enhanced load-bearing capacity and long service life, facilitating easy manufacturing and secure connections to chassis parts, while allowing for flexible joint positioning.
Implementation Method 1
The connecting element (3) is made from continuous fiber-reinforced plastic using a pultrusion process
Implementation Method 2
Plastic is injected into the mold cavity thus formed, wherein an interlocking connection is obtained between the carrier element (6, 7) thus formed and the connecting portion (9, 9')
Data Source
AI summary
A coupling rod comprises a connecting element made of a fiber-reinforced plastic by a pultrusion process, the connecting element having a strut portion with a longitudinal axis and a connecting portion; a joint element; and a carrier element connected to the connecting element and the joint element, the carrier element being made of plastic by overmolding; wherein the matrix of the fiber-reinforced plastic is a thermoset and the connecting portion is formed relative to the strut portion, wherein an interlocking connection is formed between the connecting portion and the carrier element by the overmolded carrier element. A method of producing a coupling rod is further described.