Fiber-Reinforced Thermoset Joints for Peel-Free Vehicle Assemblies
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Solution Overview
Problem
Conventional joining techniques for vehicle components require process surfaces, mechanical fasteners, and result in material-damaging peeling stresses, leading to loss of stiffness and strength, and are costly.
Innovation Solution
Using a fiber-containing, thermosetting molding compound to connect components in a form-fitting manner, eliminating the need for conventional joining methods and allowing for structurally complex assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining techniques (adhesive, mechanical fasteners) are used to connect vehicle components, then the components can be joined together, but material-damaging peeling stresses occur leading to loss of stiffness and strength
Solution Approach 1:
The patent replaces conventional mechanical joining systems (adhesives, screws, rivets) with a fiber-reinforced thermosetting molding compound that forms an integrated joint structure. This substitution eliminates the need for separate joining elements and their associated stress concentration points, thereby eliminating material-damaging peeling stresses while maintaining or improving joint strength.
Solution Approach 2:
The patent employs fiber-reinforced thermosetting molding compounds as the joining material. These composite materials combine the strength and stiffness of fibers with the bonding capabilities of thermosetting matrices, creating joints that distribute stresses uniformly without the peeling effects characteristic of conventional joining methods.
2Ease of manufacture
If conventional joining techniques are used, then components can be connected, but process surfaces and additional joining devices are required increasing complexity and cost
Solution Approach 1:
The patent merges the joining function with the component manufacturing process itself. The fiber-reinforced thermosetting molding compound is molded directly onto the component surfaces in a single integrated process, eliminating the need for separate joining operations, process surfaces, and additional joining devices.
Solution Approach 2:
The thermosetting molding compound performs multiple functions simultaneously: it provides structural reinforcement, creates the joint connection, and eliminates the need for separate joining devices. The material essentially serves its own joining function without requiring external joining systems.
3Adaptability or versatility
If conventional joining methods are used, then components can be assembled, but structurally complex and integrated assemblies cannot be achieved due to design regulations
Solution Approach 1:
The patent changes the fundamental parameters of the joining approach by using moldable fiber-reinforced thermosetting compounds that can be formed into complex three-dimensional geometries. This allows the creation of integrated, structurally complex assemblies that would be impossible with conventional joining methods subject to design regulations such as adhesive joint shear avoidance.
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
Achieves high bond strength and stiffness without material damage, enabling large and complex assemblies to be formed in a single step, reducing costs and eliminating the need for additional joining devices.
Implementation Method 1
a fiber-containing, thermosetting molding compound
Implementation Method 2
fiber-containing, thermosetting molding compound
Implementation Method 3
a cured, fiber-containing, thermosetting molding compound
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Method for joining joining sections (2, 3, 10, 12) of at least two components (4, 5, 11, 13), in particular vehicle components, the joining sections (2, 3, 10, 12) being joined exclusively using a fibrous, duroplastic molding compound.