Vehicle Node Structure with Fiber-Insert Reinforcement

Solution Overview

Problem

Existing node structures for vehicle bodies, particularly those made from fiber-reinforced plastics, face challenges in achieving optimal strength, rigidity, and crash stability while maintaining weight savings, as they often lack sufficient reinforcement in critical load-bearing areas.

Innovation Solution

A node structure composed of at least two hollow profile components connected by a reinforcing node made of unoriented short-fiber plastic with embedded oriented long-fiber inserts, which are strategically positioned to enhance local reinforcement and stiffness, using a method that involves positioning these components in a pressing tool and injecting a short-fiber plastic mass to form a strong, form-fitting connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If node structures are made from fiber-reinforced plastics to achieve weight savings, then weight is reduced, but strength and rigidity in critical load-bearing areas are insufficient

Engineering Contradiction:

ImproveweightVSAvoidstrength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies local quality by using short-fiber reinforced plastic as the base material for the connecting node, and strategically placing inserts with different fiber orientations (0°, 45°, 90°) and materials (metal, fiber-reinforced plastic, or plastic) in specific reinforcement areas where loads are transmitted. This creates locally differentiated reinforcement without making the entire node heavy, thus reducing overall weight while maintaining strength in critical areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining short-fiber reinforced plastic with inserts made of metal, fiber-reinforced plastic, or plastic with oriented fibers. This multi-material composite approach allows the connecting node to achieve high strength and rigidity in load-bearing areas while maintaining weight efficiency, resolving the contradiction between weight reduction and strength enhancement.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If fiber-reinforced plastic is used for profile components and connecting nodes, then weight savings are achieved, but crash stability and rigidity are compromised

Engineering Contradiction:

ImproveweightVSAvoidcrash stability

Core Design Contradiction:

Weight of moving objectVSStability of the object's composition

Solution Approach 1:

The patent applies local quality by using short-fiber reinforced plastic as the base material for the connecting node, and strategically placing inserts with different fiber orientations (0°, 45°, 90°) and materials (metal, fiber-reinforced plastic, or plastic) in specific reinforcement areas where loads are transmitted. This creates locally differentiated reinforcement without making the entire node heavy, thus reducing overall weight while maintaining strength in critical areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining short-fiber reinforced plastic with inserts made of metal, fiber-reinforced plastic, or plastic with oriented fibers. This multi-material composite approach allows the connecting node to achieve high strength and rigidity in load-bearing areas while maintaining weight efficiency, resolving the contradiction between weight reduction and strength enhancement.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If simple plastic material is used for connecting nodes, then manufacturing is simplified, but reinforcement in load-bearing areas is insufficient

Engineering Contradiction:

Improveease of manufactureVSAvoidstrength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies preliminary action by pre-fabricating inserts with specific fiber orientations (0°, 45°, 90°) and materials before the pressing process. These inserts are prepared in advance and then positioned in the reinforcement areas of the connecting node during the pressing operation. This approach maintains manufacturing efficiency while ensuring that reinforcement is precisely placed where needed, resolving the contradiction between manufacturing simplicity and structural strength.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies local quality by using short-fiber reinforced plastic as the base material for the connecting node, and strategically placing inserts with different fiber orientations (0°, 45°, 90°) and materials (metal, fiber-reinforced plastic, or plastic) in specific reinforcement areas where loads are transmitted. This creates locally differentiated reinforcement without making the entire node heavy, thus reducing overall weight while maintaining strength in critical areas.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP3165428B1Node structure for a vehicle body, method for its preparation and car body with at least one node structure

Publication Date: 2019.08.14 AUDI AG

Figure 1~2
Figure 3
Figure 4a~4c

AI summary

The invention relates to a node structure (110) for a vehicle body, comprising at least two profile components (120, 130) and a connecting node (160) made of fiber-reinforced plastic, which connects the profile components (120, 130) at the node-side profile ends (121, 131), wherein the connecting node (160) is made of a plastic (K) reinforced with unoriented short fibers and is additionally reinforced in at least one area with an insert (165a, 165b, 165c). The invention further relates to a method for manufacturing such a node structure (110) and a vehicle body comprising at least one such node structure (110).