Twisted Fiber-Reinforced Chassis Laminate Joint Integration
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Solution Overview
Problem
The existing production methods for chassis components with fiber-reinforced plastic laminates face challenges due to the different coefficients of expansion between metal inserts and the laminate, leading to contact corrosion and complex textile preforms required for RTM processes, especially in the integration of kinematic points in 3-point link designs.
Innovation Solution
A chassis component design where the laminate is twisted between joint receiving areas, allowing for the elimination of loops and metal inserts in certain areas, with recesses formed directly in the laminate for joint reception, enabling a simpler and corrosion-resistant production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metallic inserts (bearing bushings) are used in the area of rubber bushings to accommodate them, then the joints can be integrated into the laminate structure, but the significantly different coefficients of thermal expansion between the metallic inserts and the laminate cause contact corrosion
Solution Approach 1:
The patent removes the metallic bearing bushings from the structure entirely. Instead of using metal inserts to accommodate rubber bushings, the invention creates direct recesses in the fiber-reinforced plastic laminate that receive the rubber bushings without any metallic intermediary components, thereby eliminating the corrosion problem caused by thermal expansion differences between dissimilar metals and composite materials
Solution Approach 2:
The patent uses homogeneous material composition by replacing the metallic inserts with the same fiber-reinforced plastic laminate material. The recesses are molded directly into the laminate using the RTM process, ensuring that the surrounding structure and the recess itself are made of the same corrosion-resistant composite material, eliminating galvanic and contact corrosion issues
2Ease of operation
If circumferential loops made of fiber-reinforced plastic are used to integrate bearing bushings and rotate rubber bearings relative to the ball stud, then the joints can be properly positioned, but the loops result in very complex textile preforms for the RTM process
Solution Approach 1:
The patent removes the complex circumferential loops from the design. Instead of using loops to achieve the rotation function, the invention creates simple recesses in the laminate that directly receive the rubber bushings with their metal sleeves already integrated, eliminating the need for complex textile preforms while maintaining the rotational capability through the laminate's inherent twisted geometry
Solution Approach 2:
Instead of using additional structural elements (loops) to achieve the rotational positioning, the patent inverts the approach by embedding the rotation function directly into the laminate structure itself through its twisted geometry and recess design. The rubber bushings with integrated metal sleeves are inserted directly into these recesses, and the rotation is achieved through the laminate's built-in geometry rather than added components
3Ease of manufacture
If an internal release agent is added to the plastic matrix or the handlebar body during series production, then the demolding is facilitated, but it prevents a chemical reaction with metallic parts
Solution Approach 1:
The patent removes all metallic parts from the structure, eliminating the need for chemical bonding between the plastic matrix and metal components. The release agent can now be used freely during RTM production to facilitate demolding without any negative impact on bonding, since there are no metallic inserts or bushings that would require chemical adhesion to the composite material
Data Source
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AI summary
Disclosed is a chassis component comprising a component member (2) and a plurality of joints (3, 4), the component member (2) consisting of a laminate that is made of fiber-reinforced plastic and being provided with a plurality of joint receiving areas (5, 14) in which the plurality of joints (3, 4) are arranged one by one; the laminate is twisted in a section (16) of the component member (2) that is located between a first joint receiving area (14) and a second joint receiving area (14) such that the second joint receiving area (14) is twisted relative to the first joint receiving area (5).