Flat Reinforcing Edge Structure for Strong Composite Transitions
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Solution Overview
Problem
Existing fiber-reinforced composite components in the automotive sector face stress concentration and weak points at transition areas between injection-molded and fiber-reinforced materials due to differences in stiffness, leading to inadequate mechanical bond strength and energy absorption under high loads.
Innovation Solution
A component design featuring a planar reinforcing component enclosed on both sides by a planar material with varying wall thickness, including an overlap and ramp area, ensuring higher stiffness of the reinforcing component compared to the planar material, and utilizing indentations for stabilization during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If full-surface overmolding/forming is used to join injection-molded material and fiber-reinforced composite, then mechanical bond strength is improved, but component weight increases and manufacturing complexity increases
Solution Approach 1:
The patent divides the joining area into distinct zones: a first joining area with injection-molded material, a second joining area with fiber-reinforced composite material, and a transition area connecting them. This segmentation allows each zone to be optimized independently - the fiber-reinforced zone provides high strength where needed, while the transition area manages the stiffness mismatch, avoiding the need for full-surface overmolding and reducing overall weight.
Solution Approach 2:
The patent applies different material properties and structural characteristics to different regions of the component. The fiber-reinforced composite is used specifically in the joining area where high mechanical strength is required, while other areas use standard injection-molded material. This local optimization ensures high bond strength at the joint without increasing the weight of the entire component.
2Shape
If transition areas between injection-molded and fiber-reinforced materials are designed with existing guidelines, then visual and tactile properties are improved, but mechanical bond strength and energy absorption under high loads deteriorate
Solution Approach 1:
The transition area is designed with specific local characteristics including a gradual change in wall thickness and optimized fiber orientation that transitions from the injection-molded region to the fiber-reinforced region. This local optimization ensures both visual appeal and high mechanical strength, resolving the contradiction between aesthetic guidelines and structural performance.
Solution Approach 2:
The patent uses a composite structure in the transition area that combines features of both injection-molded material and fiber-reinforced composite material. This composite approach allows the transition zone to bridge the stiffness mismatch between the two materials while maintaining visual continuity and high mechanical strength under load.
3Stability of the object's composition
If the stiffness of injection-molded material is increased to match fiber-reinforced composite, then stress concentration at transition points is reduced, but manufacturing cost and complexity increase
Solution Approach 1:
Rather than increasing the stiffness of the entire injection-molded component, the patent segments the structure so that only the joining area uses fiber-reinforced composite material with high stiffness. The rest of the component can use standard injection-molded material with lower stiffness, maintaining manufacturing simplicity while reducing stress concentration at the transition points through proper geometric design.
Solution Approach 2:
The patent changes the wall thickness parameter in the transition area to gradually bridge the stiffness difference between injection-molded and fiber-reinforced regions. This parameter optimization allows the transition zone to accommodate the stiffness mismatch without requiring the entire component to have uniform high stiffness, thus avoiding increased manufacturing complexity.
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a component having a flat reinforcing element of a first stiffness and a flat material of a second stiffness, the first stiffness being higher than the second stiffness. The reinforcing element has a first end on a first narrow side and the material on a second narrow side has an end that bifurcates into two strips, and the two strips of the second end enclose the first end on both sides in a zone of enclosure.