Resin-Integrated Composite Structure for Moldable High-Strength Frames
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Solution Overview
Problem
Conventional composite structural bodies require deep drawing of low-strength metal plates, limiting their application to structures needing predetermined strength, and additional components increase manufacturing time and cost.
Innovation Solution
A composite structural body comprising first and second metal members with plate-like shapes integrated by a resin member, including first and second resin layers and a link portion, allowing for simpler molding and enhanced strength through insert molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If deep drawing of metal plate is performed to manufacture single-piece outer frame with recessed cross-sectional shape, then moldability is improved, but material strength is reduced and applicability to high-strength structures is limited
Solution Approach 1:
The outer frame is divided into multiple plate-like metal members joined together, avoiding the need for deep drawing of a single complex-shaped piece. This segmentation allows each member to be manufactured with simpler forming processes while maintaining high strength through the use of high-strength materials.
Solution Approach 2:
The invention uses composite construction by joining multiple metal members with resin or other joining materials. This allows the use of high-strength materials that would be difficult to form into complex shapes, while the composite structure itself provides the necessary geometric complexity and strength.
2Strength
If additional members are interposed at coupling parts or branch parts to secure strength, then structural strength is improved, but manufacturing time and cost increase
Solution Approach 1:
Multiple plate-like metal members are joined together to form an integrated outer frame structure, eliminating the need for additional reinforcing members. The joining of these members creates a unified structure that achieves the required strength without requiring extra components, thereby reducing assembly time and cost.
Solution Approach 2:
The plate-like metal members serve multiple functions: they provide structural strength, form the geometric shape of the outer frame, and create coupling interfaces through their joined configuration. This multi-functionality eliminates the need for separate reinforcing members that would otherwise be required.
3Stability of the object's composition
If single-piece outer frame with recessed cross-sectional shape is manufactured, then structural integrity is improved, but manufacturing complexity and material constraints increase
Solution Approach 1:
The outer frame is segmented into multiple plate-like metal members that are joined together. This segmentation simplifies the manufacturing of each individual member while maintaining the overall structural integrity through proper joining methods. The complex recessed cross-sectional shape is achieved through the arrangement and joining of simpler components rather than forming a single complex piece.
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 composite structural body achieves satisfactory moldability and sufficient strength, suitable for vehicle body components, with reduced manufacturing time and cost, and improved rigidity through resin integration.
Implementation Method 1
a resin member that integrates the first metal member and the second metal member with each other
Implementation Method 2
charging a molten resin being a material of the resin member into the molding space from a side where the one main surface of the first metal member and the one main surface of the second metal member are arranged; and causing the molten resin to flow through the gap between the first metal member and the second metal member
Data Source
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AI summary
A composite structural body (A) includes a first metal member (M1) having a plate-like shape, a second metal member (M2) having a plate-like shape, and a resin member (R) that integrates the first metal member (M1) and the second metal member (M2) with each other. The resin member (R) includes a first resin layer (R1) that coats astride one main surface of the first metal member (M1) and one main surface of the second metal member (M2), and a second resin layer (R2) that coats astride another main surface of the first metal member (M1) and another main surface of the second metal member (M2). The composite structural body (A) is provided as a composite structural body that has satisfactory moldability, that is capable of securing sufficient strength, and that is suitable as a component of a structure such as a vehicle body.