CFRP Vehicle Connection Member With Stable Fiber Alignment
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Solution Overview
Problem
Current methods for manufacturing carbon fiber reinforced plastics (CFRP) for vehicle structures face challenges in maintaining the unidirectionality of carbon fibers during molding processes like RTM and VARTM, leading to impaired mechanical characteristics due to fiber displacement and inadequate resin penetration, especially when using non-crimp fabrics or pre-pregs with incompatible resin formulations.
Innovation Solution
A connection member for a vehicle structure is developed using a layered structure with unidirectionally aligned carbon fibers interwoven with thermally fusible fibers, which are then cured and integrated with metal bodies, allowing for secure fiber alignment and resin impregnation, thereby maintaining fiber linearity and enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If RTM molding or VARTM molding is used to increase production output, then productivity is improved, but carbon fiber bundles become displaced due to resin flow, worsening manufacturing precision
Solution Approach 1:
The patent applies preliminary action by pre-impregnating carbon fiber bundles with matrix resin to create pre-pregs before molding. This preliminary impregnation stabilizes the carbon fiber bundles, preventing displacement during RTM or VARTM molding processes while maintaining high production output. The pre-pregs are prepared in advance with compatible resin formulations, ensuring fiber alignment is preserved throughout the molding process.
Solution Approach 2:
The patent uses an intermediary approach by introducing a binder between carbon fiber bundles during layering. This binder temporarily holds the bundles in place during molding, preventing displacement caused by resin flow. The binder serves as a mediator that maintains fiber alignment without interfering with the final matrix resin impregnation, enabling both high productivity and manufacturing precision.
2Stability of the object's composition
If a large amount of binder is applied to prevent carbon fiber displacement, then stability of composition is improved, but resin penetration becomes inadequate, worsening manufacturing precision
Solution Approach 1:
The patent applies parameter changes by carefully controlling the binder amount and properties. Instead of using a large amount of binder, the invention uses a small, optimized quantity with specific viscosity and bonding characteristics. This allows the binder to effectively prevent carbon fiber displacement while maintaining sufficient porosity and permeability for adequate matrix resin penetration, thus improving both composition stability and impregnation quality.
Solution Approach 2:
The patent applies local quality by using binder only at specific locations where carbon fiber bundles need stabilization, rather than uniformly across all fibers. The binder is applied selectively between bundles during layering, providing localized support where needed while leaving other areas open for resin penetration. This approach maintains fiber positioning stability without compromising overall resin impregnation.
3Strength
If unidirectional carbon fibers are used to maximize mechanical characteristics, then strength is improved, but fiber displacement occurs during molding, worsening reliability
Solution Approach 1:
The patent applies preliminary action by pre-impregnating unidirectional carbon fiber bundles with matrix resin to create pre-pregs before molding. This preliminary treatment stabilizes the high-strength unidirectional fibers, preventing displacement during RTM or VARTM molding. The pre-pregs maintain the linear alignment and high carbon fiber content necessary for maximum mechanical characteristics while ensuring reliable fiber positioning throughout the molding process.
Solution Approach 2:
The patent applies composite materials by combining unidirectional carbon fiber bundles with matrix resin in a pre-preg structure. This composite approach creates a stable, pre-bonded material that maintains fiber alignment and mechanical properties. The pre-preg composite prevents fiber displacement during molding while preserving the high strength characteristics of unidirectional carbon fibers, thus improving both strength and reliability.
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 solution ensures high rigidity and durability while preventing fiber displacement and resin flow issues, enabling the production of CFRP components with improved tensile and flexural elasticity, suitable for various molding methods like autoclave, press, RTM, and VARTM.
Implementation Method 1
bodies in which bundles of unidirectionally aligned carbon fibers have been interwoven with thermally fusible fibers
Implementation Method 2
the matrix resin fed into the mold after shaping does not sufficiently penetrate (impregnate) the carbon fibers
Implementation Method 3
having the carbon fibers be linear and aligned in one direction... and further having the carbon fiber content of the CFRP be as high as possible
Data Source
AI summary
An object of the present invention is to provide an innovative and highly practical connection member for a vehicle structure. The present invention is a connection member for a vehicle structure equipped with at least two connection sections (2) that are used in the vehicle structure and that connect appropriate sites within the vehicle structure, the connection member for a vehicle structure being characterized in having a layered structure section (1) configured by impregnating a layered body (4) in which a plurality of fiber bodies (3) have been layered with a matrix resin and curing the impregnated layered body, and employing, as the fiber bodies (3), bodies in which bundles of unidirectionally aligned carbon fibers (5) have been interwoven with thermally fusible fibers (6).