Vehicle Component Reference Points Molded in Fiber Plastic
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Solution Overview
Problem
Current methods for producing vehicle components from fiber-reinforced plastics face challenges in precise and reproducible positioning, often requiring manual effort and risking structural weaknesses due to machining processes that damage fibers.
Innovation Solution
The method involves generating reference points during the production process in a tool mold, using shaping elements or additional components like inserts and onserts, which allows for precise and automated positioning without damaging the fibers, ensuring the reference points are formed before curing and are integral to both manufacturing and assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reference points are generated by drilling or milling after component production, then precise positioning is achieved, but the fibers are damaged and structural strength is reduced
Solution Approach 1:
The reference points are generated during the molding process itself, before the component is completed and before any machining operations. The shaping elements are integrated into the mold, so reference points are formed automatically when the component is molded, eliminating the need for subsequent drilling or milling that would damage fibers.
Solution Approach 2:
The formation of reference points is merged with the component production process. Instead of being separate post-processing steps, the reference points are created simultaneously with the component itself through the mold's shaping elements, combining two operations into one.
2Ease of operation
If manual work steps are used for positioning fiber composite components, then positioning is achieved, but the effort and time required increase significantly
Solution Approach 1:
The component itself provides the positioning features through the integrated reference points. The shaping elements in the mold create geometric features that automatically enable precise positioning during assembly and further processing, eliminating the need for manual positioning operations.
Solution Approach 2:
Positioning features are prepared in advance during the molding process. The reference points are already present on the component when it is produced, so no additional time or effort is needed for positioning during assembly or further processing.
3Adaptability or versatility
If multiple separate operations are used for component production and positioning, then flexibility is maintained, but the process complexity and time increase
Solution Approach 1:
The production process is simplified by merging reference point formation with component molding. A single molding operation simultaneously produces the component and its positioning features, reducing the total number of operations and process complexity while maintaining flexibility for different component designs.
Data Source
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AI summary
Method for manufacturing, in particular, vehicle components (2) and/or structural components from a plastic material, wherein the vehicle components or structural components have a reference point system (RPS) for positioning during manufacturing and/or positioning during assembly with other vehicle components and/or positioning in the motor vehicle, wherein this is formed by a plurality of reference points (RP1, RP2, RP3) in the form of recesses, depressions, protrusions, edges, and planar areas.