Thermoplastic Composite Foam Component Anchoring
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Solution Overview
Problem
Existing lightweight structural components in the automotive industry face challenges with regards to stability, rigidity, and complex production processes, often requiring separate production and assembly of metal and plastic components, and struggle with integrating force-introducing elements without using welding, screws, or rivets.
Innovation Solution
A multi-layer structural component comprising a first and second fiber composite layer with a foamed plastic layer in between, featuring an anchoring structure with a branching design for simplified integration of force introduction elements, allowing for improved mechanical properties, acoustic insulation, and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If metal sheets with carrier structures connected by adhesive technology are used, then lightweight construction is achieved, but production complexity increases due to separate production and assembly steps
Solution Approach 1:
The patent combines multiple components (metal support structure, plastic cladding, and anchoring structures) into a single integrated injection molded component. This eliminates the need for separate production and assembly steps, reducing production complexity while maintaining lightweight construction benefits.
Solution Approach 2:
The injection molded component serves multiple functions simultaneously: it provides structural support, surface cladding, and integrated anchoring for force introduction elements. This multi-functionality consolidates what would otherwise require separate components and assembly operations.
2Strength
If force introduction elements are connected to load-bearing frame structures by welding, screws or rivets, then structural integrity is achieved, but workload increases
Solution Approach 1:
The anchoring structures are integrated directly into the load-bearing component through injection molding, merging the anchoring function with the structural component. This eliminates the need for separate fastening operations (welding, screwing, or riveting) while maintaining structural integrity.
Solution Approach 2:
The anchoring structures are formed as integral parts of the component during the injection molding process itself, before assembly. This preliminary formation of anchoring features eliminates subsequent fastening operations and reduces assembly workload.
3Weight of moving object
If separate metal and plastic components are produced and then assembled by gluing, then lightweight construction is achieved, but production complexity increases
Solution Approach 1:
The patent produces the entire structural component with cladding and anchoring features in a single injection molding operation, eliminating multiple production steps and assembly operations. This significantly improves production efficiency while maintaining the lightweight characteristics of plastic components.
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 provides structural components with enhanced rigidity, stability, and acoustic insulation, enabling direct installation in vehicles without additional frame structures and simplifying the attachment of force introduction elements, while maintaining a lightweight and high surface quality.
Implementation Method 1
the foam layer made of foamed plastic arranged in between
Implementation Method 2
each having at least one fiber layer made of a fiber material, which is divided into a layer on a thermoplastic Plastic-based matrix is embedded
Data Source
Figure 1~3
Figure 4a~4c
Figure 5~6b
AI summary
The invention relates to a multilayer structural component (84, 110, 120, 170) comprising a first and a second fibre-composite layer (102, 104, 122, 124, 172, 174) and a foam layer (106, 126, 176), arranged in between, made of foamed plastics material, wherein the first and the second fibre-composite layer (102, 104, 122, 124, 172, 174) each have at least one fibrous layer (4, 16, 18, 24) made of a fibre material, said fibrous layer being embedded in a thermoplastic-based matrix (8, 20). The structural component has an anchoring structure (140) for attaching to a force introduction element. The invention furthermore relates to a method for producing a structural component (84, 110, 120, 170), in which a first and a second fibre-composite sheet (2, 12, 48, 52) are provided, wherein the first and the second fibre-composite sheet (2, 12, 48, 52) each have at least one fibrous layer (4, 16, 18, 24) made of a fibre material, said fibrous layer being embedded in a thermoplastic-based matrix (8, 20), in which the first fibre-composite sheet (2, 12, 48, 52) is thermoformed to form a first fibre-composite semifinished product (64, 86, 88) and the second fibre-composite sheet (2, 12, 48, 52) is thermoformed to form a second fibre-composite semifinished product (64, 86, 88), in which the first and the second fibre-composite semifinished product (64, 86, 88) are arranged in a foaming mould (90) such that a cavity (96) is formed between the first and the second fibre-composite semifinished product (64, 86, 88), and in which the cavity (96) is foamed by injection of a foaming plastics material. Furthermore, the anchoring structure (140) is integrated into the structural component.