CFRP Rear Frame Wear Detection via Embedded Color Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing exterior parts for saddled vehicles, such as engine guards, made of aluminum or carbon fiber reinforced plastic (CFRP), face challenges in determining the optimal replacement time due to lack of visible wear indicators, leading to premature or delayed replacement.
Innovation Solution
A CFRP laminate with a different color layer embedded between carbon fiber layers, allowing the exposed different color layer to be visible when the outer carbon fiber layer is worn, providing a clear visual cue for replacement timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an exterior part is made of CFRP to achieve high rigidity and light weight, then the rigidity and weight performance are improved, but the ability to visually recognize wear and replacement timing deteriorates
Solution Approach 1:
The patent applies color change principle by embedding a different color layer within the CFRP laminate structure. When the outer carbon fiber layers are worn away due to gravel impact, the exposed different color layer provides a clear visual indicator that the exterior part has reached its replacement threshold, solving the problem of unrecognized wear in high-performance CFRP components.
Solution Approach 2:
The patent implements nesting by placing the different color layer inside the multi-layer CFRP structure, similar to nested dolls. The different color layer is embedded between carbon fiber layers, creating a hidden indicator that becomes visible only when the outer protective layers are worn away, allowing wear detection without compromising the structural integrity of the CFRP.
2Strength
If the exterior part is made of aluminum plate to achieve high rigidity, then the strength is improved, but the weight increases and visual recognition of wear remains difficult
Solution Approach 1:
The patent uses composite materials by combining carbon fiber reinforced plastic with a different color indicator layer. This composite structure maintains the high rigidity requirements of traditional aluminum engine guards while significantly reducing weight, and additionally provides visual wear indication capability that aluminum lacks.
3Productivity
If the exterior part is used for extended period to reduce replacement frequency, then productivity is improved, but the risk of undetected wear and sudden failure increases
Solution Approach 1:
The patent applies preliminary action by providing advance visual warning through the exposed different color layer before the exterior part reaches critical failure point. This allows operators to plan and schedule replacements proactively, maintaining both high productivity through reduced unexpected downtime and high reliability through timely replacement before sudden failure occurs.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Object To enable easy visual recognition of an optimum replacement timing in order to rectify a situation in which, even when a lost portion is produced by, for example, flying gravel during traveling in a carbon fiber reinforced plastic used as an exterior part and necessity of replacement arises, the lost portion is hard to be visually recognizable and the optimum replacement timing is hard to be determined. Solving Means A rear frame 20 is formed of a laminate 70 that includes a plurality of carbon fiber layers laminated one on top of another and hardened and integrated with each other by a plastic. A different color layer 37 having a color different from a color of the carbon fiber layers 36 is disposed between the carbon fiber layers 36 in the laminate 70. When a carbon fiber layer 36 on the outside is lost by a piece of flying gravel 60 and a lost portion 38 reaches the different color layer 37, a surface of the different color layer 37 is exposed from the lost portion 38. An exposed portion 39 having the different color can be easily recognized from the outside. The appearance of the exposed portion 39 allows arrival of a replacement time of the rear frame 20 to be recognized.