Anisotropic Reinforced Plastic Layer Stack for Automotive Structural Parts
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Solution Overview
Problem
Current manufacturing processes for automotive structural parts, particularly those made of steel and composite materials, face challenges in achieving significant weight reduction while maintaining mechanical strength, as they require complex processes and additional equipment, leading to increased costs and complexity.
Innovation Solution
A multilayer composite with anisotropic construction is used, where layers with different reinforcing elements are oriented according to expected stress directions, allowing for reduced thickness and reinforcement, thereby achieving weight reduction while maintaining or enhancing mechanical resistance in specific directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural parts are made of steel to ensure high mechanical strength, then the mechanical resistance is improved, but the weight of the part increases
Solution Approach 1:
The patent uses composite materials consisting of multiple layers with different reinforcing elements (glass fibers, carbon fibers, aramid fibers) embedded in a plastic matrix. This allows achieving high mechanical strength while significantly reducing weight compared to traditional steel structural parts.
Solution Approach 2:
The patent applies different types of reinforcing elements in specific layers according to the local stress requirements. Glass fibers are used in peripheral layers for general reinforcement, while carbon or aramid fibers are placed in internal layers where higher strength is needed, optimizing both weight and mechanical performance.
2Weight of moving object
If multiple steel grades and thicknesses are used to reduce weight while maintaining strength, then the weight reduction is achieved, but the manufacturing process complexity increases
Solution Approach 1:
The patent divides the structural part into multiple layers, each with specific reinforcing elements oriented in particular directions. This segmentation allows optimizing weight and strength in different areas while maintaining a unified manufacturing process using compression molding, avoiding the need for multiple steel grades and assembly operations.
Solution Approach 2:
The patent changes the orientation and type of reinforcing elements in different layers to achieve the desired mechanical properties and weight reduction, all within a single composite manufacturing process. This avoids the complexity of managing multiple steel grades, thicknesses, and assembly operations.
3Weight of moving object
If layers are reduced in thickness and reinforcement quantity to achieve weight reduction, then the weight decreases, but the mechanical resistance may be compromised
Solution Approach 1:
The patent strategically places high-strength reinforcing elements (carbon fibers, aramid fibers) in internal layers where they provide maximum structural support, while using lighter glass fibers in peripheral layers. This local optimization maintains mechanical resistance while minimizing overall weight.
Solution Approach 2:
The patent uses a composite structure combining different types of fibers (glass, carbon, aramid) with a plastic matrix, where each material contributes specific mechanical properties. This composite approach allows achieving high strength-to-weight ratio that would not be possible with single-material construction.
4Weight of moving object
If aluminum castings are used to create structures with locally adapted thicknesses, then the weight reduction is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent uses composite materials with strategically oriented reinforcing elements to achieve locally optimized strength and weight characteristics, eliminating the need for aluminum castings and their associated complexity. The composite layers can be directly molded into the final shape, simplifying manufacturing and assembly.
Data Source
Figure 1
AI summary
The invention relates to a stack (1) for moulding parts in a plastic material, comprising an assembly of layers, each layer (2) comprising a plastic material (MP) and at least one reinforcing element (ER) having at least one main slenderness direction (DP), characterised in that the reinforcing elements (ER) of one layer have at least one main slenderness direction which is different from that of the reinforcing elements of at least one other layer, said different main slenderness direction being selected so as to define a direction of voluntary anisotropy in the stack (1).