3D Composite Board Perpendicular Pressure Resistance
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Solution Overview
Problem
The existing composite boards, as described in European patent EP-B-0591324, are not capable of withstanding great pressures applied perpendicular to their laying plane, limiting their use to surfaces that cannot support human traffic, such as partition walls.
Innovation Solution
A layered composite structure is created using multiple three-dimensional fabrics interconnected by filaments, impregnated with synthetic thermosetting resin, compressed, and then expanded to align filaments perpendicular to the board's surface, enhancing structural robustness and allowing for the creation of load-bearing surfaces like floors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a simple fabric structure with thermosetting resin is used, then the board has reduced weight and simple structure, but it cannot withstand great pressures applied perpendicular to the laying plane
Solution Approach 1:
The patent uses a composite structure combining multiple fabric types (bidirectional fabric layers and three-dimensional fabric layers) with thermosetting resin. The bidirectional fabrics provide baseline strength while the three-dimensional fabrics with vertical filaments add perpendicular pressure resistance. This composite approach achieves high strength without excessive complexity by strategically combining different fabric architectures.
Solution Approach 2:
The patent introduces three-dimensional fabric layers with filaments extending in the vertical direction (perpendicular to the board plane), adding a third dimension to the traditionally planar bidirectional fabric structure. This dimensional addition directly addresses the weakness of perpendicular pressure resistance while maintaining relative structural simplicity through standardized layering.
2Strength
If multiple three-dimensional fabric layers are added to enhance strength, then the board can support concentrated loads, but the manufacturing process becomes more complex
Solution Approach 1:
The patent divides the reinforcement function into separate modular layers: bidirectional fabric layers for baseline strength and distinct three-dimensional fabric layers for perpendicular load bearing. Each layer type can be independently selected and positioned based on specific performance requirements, allowing manufacturers to optimize the stack-up configuration without redesigning the entire structure.
Solution Approach 2:
The fabric layers are pre-formed with their specific architectures (bidirectional or three-dimensional) before assembly into the final board structure. This preliminary preparation of standardized fabric components simplifies the manufacturing process by eliminating the need for complex in-situ fabrication during board production.
3Strength
If the press is opened to expand and align filaments, then the board achieves enhanced structural robustness, but the manufacturing time increases
Solution Approach 1:
The patent utilizes the phase transition of thermosetting resin from liquid (during impregnation and compression) to solid (during curing) to lock the fabric layers in their compressed, aligned configuration. The resin cures while the press is closed, maintaining pressure and alignment, then the press opens to reveal the already-structured robust board. This phase transition approach achieves structural enhancement without requiring additional time-consuming expansion steps.
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
The resulting board is extremely robust, capable of supporting concentrated loads, and features internal channels for fluid conveyance, enabling its use in applications like train or ship flooring while ensuring safe fluid transportation.
Implementation Method 1
compressing the layered structure with a heated press
Implementation Method 2
carrying out the polymerization of the resin impregnating the layered structure
Implementation Method 3
compressing the layered structure with a heated press in such a way that the resin is evenly distributed between the various elements of the layered structure
Implementation Method 4
expanding the previously compressed layered structure opening the press in a controlled manner in such a way that the filaments of the first, second and third three-dimensional fabric stretch and arrange themselves substantially perpendicular to the laying planes
Data Source
Figure 1
Figure 2~3
AI summary
A method for making a composite board, wherein a layered structure is manufactured, which comprises three three- dimensional fabrics overlapping each other, impregnated with resin ans interposed between a pair of detaching sheets. The layered structure is compressed by means of a heated press, so that the resin can spread uniformly. Subsequently, the layered structure is allowed to expand, so that the filaments of the three-dimensional fabrics stretch and arrange themselves substantially perpendicular to the laying planes of the fabric sheets forming the three-dimensional fabrics. After the polymerization of the resin impregnating the layered structure, the latter is taken out of the press and the detaching sheets are removed, thus obtaining a finished board.