Composite Gap Material Orthogonal Load Resistance
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Solution Overview
Problem
Reinforcement fibers in filler bodies of composite materials are prone to cracking under loads orthogonal to their longitudinal direction due to separation, leading to potential defects.
Innovation Solution
Incorporating a gap fiber sheet with reinforcement fibers oriented differently from the longitudinal direction, combined with gap reinforcement fibers oriented in the same direction, to provide drag and enhance the material's strength, along with even distribution and contact with the gap fiber sheet to prevent uneven reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reinforcement fibers are oriented in the longitudinal direction of the beam material, then the manufacturing process is simplified and fibers are easily aligned, but the gap material becomes weak against loads acting in directions orthogonal to the longitudinal direction, causing fiber separation and cracking
Solution Approach 1:
The gap material is constructed as a composite structure containing two distinct types of reinforcement fibers: gap reinforcement fibers oriented in the longitudinal direction and gap fiber sheet containing fibers oriented in directions different from the longitudinal direction. This composite fiber arrangement allows the material to resist both longitudinal and orthogonal loads effectively, resolving the contradiction between ease of manufacture and strength against orthogonal load.
Solution Approach 2:
The invention introduces multi-directional fiber orientation by incorporating a gap fiber sheet with fibers arranged in directions different from the longitudinal direction. This adds dimensional complexity to the fiber arrangement, enabling the material to withstand loads from multiple directions while maintaining manufacturing feasibility through the structured layering approach.
2Device complexity
If gap reinforcement fibers are concentrated in specific areas, then manufacturing complexity is reduced, but uneven distribution causes defects and reduces overall structural integrity
Solution Approach 1:
The gap fiber sheet is positioned at specific locations within the beam material where orthogonal load resistance is most needed, such as in gap portions between reinforcement fiber bundles. This localized placement of multi-directional fibers provides targeted reinforcement while maintaining overall manufacturing simplicity and structural reliability.
Data Source
AI summary
This pultrusion material that is a composite material member comprises: a plurality of fiber sheets that extend along a lengthwise direction; and a gap material that is provided to a gap formed by the plurality of fiber sheets, wherein the gap material has a gap fiber sheet including reinforcement fibers that are oriented in a different fiber direction than the lengthwise direction, and has gap reinforcement fibers that are oriented in the same fiber direction as the lengthwise direction. Additionally, the gap reinforcement fibers are provided evenly distributed in a cross-section of the gap material, said cross-section being perpendicular to the lengthwise direction.