Sealed Planar Reinforcement for Weldable, Leak-Tight Parts
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Solution Overview
Problem
Reinforcement components made from organosheets lack weldability due to a matrix-poor surface layer and are prone to perforations during handling, which can compromise the integrity of components like fuel tanks and battery housings.
Innovation Solution
A planar reinforcement component with a higher stiffness than its attachments, which can be welded and used to seal perforations, allowing additional components to be attached and ensuring leak-tight systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If organosheets are used as reinforcement components, then weight reduction and mechanical performance are improved, but weldability deteriorates due to matrix-poor surface layer
Solution Approach 1:
A sealing attachment made of thermoplastic material is introduced as an intermediary component between the organosheet reinforcement and the welding process. This attachment serves as a mediator that provides a weldable surface while the organosheet maintains its structural function, thus resolving the contradiction between mechanical performance and weldability
Solution Approach 2:
The solution combines the organosheet reinforcement component with a thermoplastic sealing attachment to create a composite structure. The organosheet provides high mechanical performance while the thermoplastic attachment provides weldability, thus resolving the contradiction through material composition
2Ease of operation
If organosheets are handled during transport and manufacturing, then component assembly is enabled, but perforations occur due to gripping tools
Solution Approach 1:
Sealing attachments are pre-positioned or applied to the organosheet before handling operations. These attachments preemptively seal potential perforation sites created by gripping tools during transport and assembly, thus resolving the contradiction between ease of handling and integrity
Solution Approach 2:
The sealing attachment acts as a protective layer that cushions against the harmful effects of gripping tools. By providing this protective barrier beforehand, the organosheet is shielded from perforations during handling operations
3Productivity
If direct welding is applied to organosheet surface, then joining speed is improved, but bonding quality deteriorates due to high fiber content in surface layer
Solution Approach 1:
The thermoplastic sealing attachment serves as an intermediary layer between the welding tool and the organosheet surface. This mediator provides a suitable bonding surface for welding processes, ensuring high bonding quality while maintaining efficient joining speeds
Solution Approach 2:
The sealing attachment changes the surface parameters of the organosheet by providing a thermoplastic surface with appropriate bonding characteristics. This parameter change enables effective welding while preserving the high-speed joining capability
Data Source
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AI summary
The invention relates to a part (1) comprising a flat reinforcement component (2) having a first stiffness and a flat attachment (3) consisting of an attachment material having a second stiffness, the first stiffness being greater than the second stiffness, wherein the flat reinforcement component has an upper face and a lower face, and the attachment (3) is attached at least to the upper or lower face of the flat reinforcement component (2) in a first portion of the flat reinforcement component (2).