Fiber-Reinforced Composite Drainage Cover with Foam Core
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Solution Overview
Problem
Current plastic covers for drainage channels lack the necessary load-bearing capacity for high-traffic areas due to inferior mechanical properties compared to steel or cast steel, requiring more material and resulting in heavier, more expensive constructions.
Innovation Solution
A composite material structure for cover gratings featuring a dimensionally stable core with long, unidirectionally aligned continuous fibers in the top and bottom cover fabrics, supported by intermediate layers with short or long fibers, and a thermoplastic matrix system, allowing for a lighter, cost-effective design that can withstand high static and dynamic loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic covers are used for drainage channels, then they offer advantages such as being rust-proof, anti-magnetic, and lightweight, but they lack the necessary load-bearing capacity for high-traffic areas compared to steel or cast steel
Solution Approach 1:
The patent applies composite materials by combining fiber-reinforced plastic layers with a foam core structure. The fiber-reinforced layers provide tensile strength and load-bearing capacity, while the foam core provides compressive strength and structural support. This composite construction enables plastic covers to achieve high load classes (D400, E600, F900) comparable to steel while maintaining the advantages of being rust-proof, anti-magnetic, and lightweight.
Solution Approach 2:
The patent implements local quality by varying the material composition and thickness in different areas of the cover. The fiber-reinforced plastic layers are strategically positioned in areas experiencing tensile stresses, while the foam core provides support in compressive zones. This localized optimization of material properties maximizes load-bearing capacity while minimizing overall material usage and weight.
2Reliability
If more material is used to achieve higher load classes in plastic covers, then load-bearing capacity increases, but the construction becomes heavier and more expensive
Solution Approach 1:
The composite structure of fiber-reinforced plastic layers combined with foam core allows achieving high load-bearing capacity with reduced material quantity. The fibers provide high strength-to-weight ratio, while the foam core provides structural support with minimal weight. This enables the cover to meet high load classes without the excessive weight that would result from using solid plastic or metal alternatives.
Solution Approach 2:
The patent changes material parameters by using fiber-reinforced plastics with specific fiber orientations and volumes, combined with foam cores of varying density. This parameter optimization allows achieving maximum load-bearing capacity with minimum material usage, thereby reducing both weight and production cost while meeting high load class requirements.
3Reliability
If fiber-reinforced plastics are used to improve mechanical properties, then load-bearing capacity increases, but production cost increases due to expensive engineering plastics
Solution Approach 1:
The patent uses composite materials where fiber-reinforced plastic layers are combined with a foam core. This combination allows achieving high load-bearing capacity with optimized material usage. The foam core reduces the overall material quantity required, thereby reducing the amount of expensive engineering plastic needed while maintaining structural integrity and load-bearing performance.
Solution Approach 2:
By applying fiber-reinforced plastic only in specific layers and areas where tensile strength is needed, rather than throughout the entire cover structure, the patent optimizes material usage. The foam core provides support in areas where full fiber reinforcement is not necessary, reducing overall material cost while maintaining required mechanical properties.
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 structure achieves high resilience and load-bearing capacity while maintaining a lightweight and cost-effective production, with the composite material design effectively distributing stresses and reducing material usage.
Implementation Method 1
The cover fabrics (6, 7) and the core (5) are integrally bonded to one another in a materially bonded manner, with the aid of a thermoplastic matrix system
Implementation Method 2
The cover fabrics (6, 7) are formed from a fiber-reinforced composite material with long, aligned, unidirectional or, particularly preferably, continuous fibers
Implementation Method 3
the transverse ribs have a dimensionally stable core which is integrally received between an upper-side cover fabric and a lower-side cover fabric
Data Source
Figure 1~2
Figure 3~4
AI summary
Load-bearing semi-finished structure, in particular cover grate or manhole cover for drainage channels, drain or inlet boxes or shafts, comprising lateral support areas (2) with longitudinal beams (3), as well as a plurality of transverse ribs (4) extending between the longitudinal beams (3), wherein the transverse ribs (4) have a dimensionally stable core (5) which is materially bonded between an upper cover layer (6) and a lower cover layer (7), characterized in that the upper cover layer (6) and the lower cover layer (7) are each formed from a fiber-reinforced composite material with one or more layers of similarly oriented long or continuous fibers and together with the dimensionally stable core (5) form a multi-layered, functionally graded multi-material composite.