Fiber-Reinforced Resin Bonded Structure with Variable Adhesive Thickness
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Solution Overview
Problem
The challenge in manufacturing fiber-reinforced resin bonded structures, such as vehicle body components, is controlling the adhesive layer thickness uniformly, especially in complex three-dimensional shapes, which often results in reduced adhesive strength and reliability due to the use of glass beads, leading to potential cracks and stress concentration points.
Innovation Solution
The solution involves an adhesive layer with distinct regions of varying thickness, where glass beads act as spacers in thicker regions and destruction preventing members made of organic materials are used in thinner regions to maintain a consistent adhesive layer thickness and prevent cracks, ensuring higher bonding strength, particularly around bends and stress-concentrated areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If glass beads are used to control adhesive layer thickness, then adhesive layer thickness can be controlled, but adhesive strength decreases and cracks may occur
Solution Approach 1:
The adhesive layer is divided into multiple regions with different thicknesses (first regions with larger thickness and second regions with smaller thickness). This segmentation allows different functional requirements to be met in different areas, achieving both thickness control and high adhesive strength without relying on glass beads that cause cracking.
Solution Approach 2:
Different regions of the adhesive layer are given different thickness characteristics tailored to their specific functional needs. The first regions have larger thickness for stress distribution while the second regions have smaller thickness for high bonding strength, optimizing performance locally in each region rather than using a uniform thickness throughout.
2Reliability
If adhesive layer thickness is reduced to improve adhesive strength, then bonding strength increases, but control of thickness becomes more difficult in complex geometries
Solution Approach 1:
The adhesive layer is segmented into multiple regions with different thickness characteristics. This allows the thickness to be optimized for each specific region's functional requirements while maintaining overall control, solving the dilemma between achieving high strength through thin layers and maintaining controllability in complex geometries.
Solution Approach 2:
The adhesive layer thickness is tailored locally to match the specific requirements of each region. Areas requiring high bonding strength have thinner adhesive layers, while areas requiring stress distribution or accommodating geometric complexity have thicker layers, achieving optimal performance throughout the entire bonded structure.
3Ease of manufacture
If uniform adhesive layer thickness is used, then manufacturing is simpler, but adhesive strength is reduced in stress-concentrated areas
Solution Approach 1:
Rather than using a uniform adhesive layer, the adhesive layer is segmented into multiple regions with different thicknesses. This segmentation enables the adhesive strength to be optimized in stress-concentrated areas while maintaining relatively simple manufacturing processes, as the segmentation follows functional requirements rather than requiring complex manufacturing steps.
Solution Approach 2:
The adhesive layer thickness is customized for each region based on its specific functional requirements. Stress-concentrated areas receive thinner adhesive layers for higher bonding strength, while other areas have thicker layers for stress distribution, achieving locally optimized strength without compromising manufacturing feasibility.
Data Source
AI summary
A fiber-reinforced resin bonded structure includes a first member, a second member, and an adhesive layer that bonds the first member and the second member. One or both of the first member and the second member are made of a fiber-reinforced resin composite. The adhesive layer includes at least one first region having a relatively large layer thickness and a second region having a relatively small layer thickness. The at least one first region of the adhesive layer includes a spacer in contact with the first member and the second member.