Multilayer Structural Component With Stiffened Aluminum Layers
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Solution Overview
Problem
The production of multi-layer structural components for vehicle underbody areas is costly due to complex production processes involving expensive aluminum supporting structures, which require separate manufacturing, cutting, welding, and coating before integration with fiber mats and metal intermediate layers.
Innovation Solution
The use of flanged edge aluminum layers with stiffening structures, such as beaded edges and recesses, embedded within a layered structure comprising fiber and thermoplastic materials, allows for simpler and cost-effective production by replacing complex support structures with easily produced and pre-painted aluminum sheets, enhancing rigidity and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex aluminum supporting structures are used to improve mechanical properties, then rigidity and strength are enhanced, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent combines the aluminum layer with fiber-reinforced plastic layers into a single integrated multilayer component, eliminating the need for separate aluminum supporting structures. The aluminum layer is directly formed with stiffening profiles integrated into the layered structure, merging previously separate manufacturing steps into one cohesive process that reduces complexity while maintaining mechanical strength.
Solution Approach 2:
The aluminum layer is pre-formed with stiffening profiles and surface treatments before being integrated into the final component. This preliminary shaping and preparation of the aluminum layer allows for simplified subsequent assembly and bonding processes, reducing overall manufacturing complexity while ensuring the required mechanical properties are achieved.
2Reliability
If separate manufacturing steps including welding and coating are used, then structural integrity and corrosion resistance are improved, but production time and costs increase
Solution Approach 1:
The patent merges multiple separate manufacturing operations into a single integrated process. The aluminum layer is simultaneously formed, bonded to fiber-reinforced plastic layers, and surface-coated in one continuous operation, eliminating the need for separate welding and coating steps while maintaining structural integrity and corrosion resistance.
Solution Approach 2:
The invention uses composite material structures where aluminum layers are bonded to fiber-reinforced plastic layers, creating a hybrid material system that achieves both structural integrity and corrosion resistance through material properties and interlayer bonding rather than through separate welding and coating operations.
3Object-affected harmful factors
If traditional multilayer construction with fiber composite cladding and sheet metal is used, then acoustic and visual functions are achieved, but assembly effort and weight increase
Solution Approach 1:
The patent merges fiber composite cladding, aluminum supporting structures, and acoustic insulation layers into a single integrated multilayer component. This consolidation eliminates multiple separate assembly operations while maintaining acoustic insulation properties, as the different functional layers are bonded together in one manufacturing process rather than assembled separately.
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
This approach results in a more cost-effective structural component with improved mechanical properties, including flexural, torsional, and compressive rigidity, while maintaining corrosion resistance and reducing production costs through streamlined manufacturing processes.
Implementation Method 1
at least one fiber layer made of a fiber material and a thermoplastic binder
Data Source
Figure 1a~1d
Figure 2
Figure 3a
AI summary
The invention relates to a multi-layered structural component (60, 100) having a layer structure (8) comprising a plurality of layers (4, 6) arranged one atop the other in a stacking direction, wherein the layer structure (8) comprises at least one fiber structure (6) consisting of a fiber material and of a thermoplastic binding agent, and at least one aluminum layer (4) made of aluminum or of an aluminum alloy and wherein at least one aluminum layer (4) of the layer structure (8) has a stiffening structure (50, 78, 94; 56, 74; 98) and/or a recess (48, 76). The invention further relates to a method for producing such a structural component (60, 100) and to uses therefor.