Vehicle Frame FRP Adhesive Bonding Structure
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Solution Overview
Problem
Vehicle frame structures reinforced with fiber reinforced plastic (FRP) members face challenges in controlling costs and maintaining adhesiveness between FRP and metal components, with configurations using randomly oriented fibers being cost-effective but prone to adhesive flow and reduced adhesiveness.
Innovation Solution
A vehicle frame structure design incorporating a combination of two FRP members with differently oriented fibers, where a second fiber reinforced plastic member with continuous fibers is used in a thinner configuration between an adhesive layer and a first FRP member with randomly oriented fibers, reducing adhesive flow and maintaining adhesiveness while controlling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a fiber reinforced plastic member including randomly oriented fibers is used to reinforce a vehicle frame member, then cost is reduced, but adhesiveness between the vehicle frame member and the fiber reinforced plastic member deteriorates due to adhesive flow during heating
Solution Approach 1:
The reinforcement structure is segmented into two distinct FRP members: a first FRP member with randomly oriented fibers for cost-effectiveness and a second FRP member with aligned fibers for adhesive flow control. This segmentation allows each layer to perform its specific function, resolving the contradiction between cost and adhesiveness.
Solution Approach 2:
The second FRP member with aligned fibers acts as an intermediary layer between the adhesive and the first FRP member. This intermediary layer controls adhesive flow during heating while the first FRP member maintains cost-effectiveness, thus resolving the contradiction between cost and adhesiveness.
2Reliability
If a fiber reinforced plastic member including continuous fibers is used to reinforce a vehicle frame member, then adhesiveness is maintained, but cost increases
Solution Approach 1:
The second FRP member with aligned fibers is applied locally only where adhesive bonding occurs, rather than throughout the entire reinforcement area. This local application maintains adhesiveness at the critical bonding interface while minimizing the use of expensive continuous fiber material, thus resolving the cost-adhesiveness contradiction.
Solution Approach 2:
Instead of using continuous fibers throughout the entire FRP member, the solution applies aligned continuous fibers only in the second layer where adhesive bonding occurs. This partial application of continuous fibers provides the necessary adhesive flow control without the excessive cost of using continuous fibers throughout the entire reinforcement structure.
3Ease of manufacture
If heating is applied to soften the resin to configure the base member, then the fiber reinforced plastic member can be formed, but the adhesive becomes liable to flow reducing adhesiveness
Solution Approach 1:
The second FRP member with aligned fibers serves as a mediator that controls adhesive flow during the heating process. The aligned fiber structure provides a physical barrier that restricts adhesive movement while allowing the resin to be softened and formed, thus resolving the contradiction between formability and adhesiveness.
Solution Approach 2:
The invention changes the fiber orientation parameter in the second FRP member from random to aligned, which fundamentally alters the adhesive flow behavior during heating. This parameter change allows the adhesive to be controlled during the heating and forming process while maintaining adhesiveness, resolving the contradiction between formability and bonding strength.
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 design effectively suppresses cost increases and adhesiveness reductions between the vehicle frame and FRP members, enhancing bending rigidity and deformation resistance while minimizing weight and material strength losses.
Implementation Method 1
The vehicle frame structure is formed by applying heat and pressure in a state in which in which the vehicle frame member, the adhesive member, the second fiber reinforced plastic member, and the first fiber reinforced plastic member are superimposed on each other in the thickness direction
Implementation Method 2
The vehicle frame structure is formed by applying heat and pressure in a state in which in which the vehicle frame member, the adhesive member, the second fiber reinforced plastic member, and the first fiber reinforced plastic member are superimposed on each other in the thickness direction
Implementation Method 3
The second fiber reinforced plastic member that includes the plural oriented second fibers has a greater contact surface area between fibers than the first fiber reinforced plastic member that includes the plural first fibers oriented in different directions. In other words, when the second fiber reinforced plastic member is heated, the resin base material does not readily flow in directions intersecting the orientation direction of the fibers
Data Source
AI summary
A vehicle frame structure includes: an adhesive member that is superimposed on and adhered to a plate shaped vehicle frame member extending in one direction such that the adhesive member is superimposed in a thickness direction of the vehicle frame member; a first fiber reinforced plastic member that includes plural first fibers oriented in different directions to each other, and that is disposed spaced apart from the vehicle frame member in the thickness direction; and a second fiber reinforced plastic member that includes plural second fibers oriented in an orientation direction of an intersecting direction intersecting the thickness direction, that has a thinner thickness in the thickness direction than a thickness of the first fiber reinforced plastic member, and that is sandwiched between the adhesive member and the first fiber reinforced plastic member in the thickness direction.