Vehicle Coupling with Bulk Plastic Force Fit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle coupling constructions, such as those made from cast steel or welded sheet metal, are heavy and costly due to high processing expenses and require minimum wall thicknesses for welding or casting, which is inefficient for low mechanical loads and can have weak spots under high dynamic loads.
Innovation Solution
A vehicle coupling with a structural element force-fitted to a coupling body using bulk plastic material, allowing for reduced manufacturing costs, complex geometries, and the use of thinner metal sheets, along with reinforcement ribs and holders, and the option of using metal, carbon fiber, or fiber glass for structural elements, which can be molded or encapsulated within the plastic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cast steel or nodular cast iron is used for the coupling body, then strength and robustness are improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent applies local quality by using a sheet metal coupling body with strategically placed reinforcement ribs only in areas requiring high strength, rather than making the entire coupling body from heavy cast material. This allows the coupling to have sufficient strength where needed while maintaining lower overall weight through thinner metal sheets in non-critical areas.
Solution Approach 2:
The patent employs composite materials by combining sheet metal with plastic material for the reinforcement ribs and holders. This hybrid construction leverages the strength of metal where needed and the weight-saving properties of plastic for non-load-bearing or less critical structural elements, achieving an optimal balance between strength and weight.
2Ease of manufacture
If welded sheet metal parts are used to construct the coupling body, then ease of manufacture is improved, but manufacturing cost and processing expenses increase
Solution Approach 1:
The patent merges multiple manufacturing operations into a single injection molding process. The coupling body, reinforcement ribs, and holders are all formed and assembled in one step using injection molding, eliminating the need for separate welding operations and reducing processing expenses while maintaining ease of manufacture.
3Ease of manufacture
If minimum wall thicknesses are used for welding or casting, then manufacturing feasibility is improved, but weight and material usage increase
Solution Approach 1:
The patent changes the manufacturing parameter from traditional welding/casting minimum wall thicknesses to injection molding-compatible thicknesses. This allows the use of thinner metal sheets and wall thicknesses that would be insufficient for welding or casting but are perfectly suitable for injection molding, thereby reducing weight while maintaining manufacturing feasibility.
4Strength
If welding constructions are used for high dynamic loads, then strength is improved, but reliability decreases due to weak spots at weld seams
Solution Approach 1:
The patent replaces the mechanical welding system with an injection molding system. Instead of joining parts through welding (which creates stress concentration points and weak spots), the design uses an injection molded coupling body with integrated reinforcement ribs and holders that are formed as part of the same structure, eliminating weld seams and their associated reliability issues while maintaining strength under high dynamic loads.
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
This approach results in a lighter, cost-effective vehicle coupling with enhanced strength and corrosion protection, capable of handling both low and high mechanical loads without the weaknesses of traditional welding constructions.
Implementation Method 1
the structural element is force fit to the coupling body by means of a bulk plastic material
Implementation Method 2
the structural element is force fit to the coupling body by means of a bulk plastic material
Implementation Method 3
The metal foam is made from a foaming agent and a metal powder added thereto, wherein the metal powder consists in most cases of aluminum or steel. After foaming agent and metal powder are brought together and mixed, a first forming process and a subsequent foaming takes place. The foam structure results in very low volume density while the strength of the metal foam is only insignificantly reduced.
Data Source
AI summary
A vehicle coupling, and a method for the manufacture thereof, having a coupling body (1) and at least one structural element (2) placed thereon wherein the structural element (2) is force fit to the coupling body (1) using a bulk plastic material (3).