Composite Material Inner Outer Member Joining
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Solution Overview
Problem
Existing composite materials with unidirectional or random reinforcing fibers face challenges in achieving complex shapes without compromising strength.
Innovation Solution
A method involving the insertion of a resin-impregnated inner member with unidirectional reinforcing fibers into an outer member with woven, undulating first reinforcing fibers, followed by curing to form a composite material that maintains strength and allows for complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a unidirectional material or random material is laminated to form a member, then the strength of the compact increases, but it is difficult to realize a complex shape
Solution Approach 1:
The invention divides the composite material into two distinct components: an outer member made of woven fabric with high flexibility for forming complex shapes, and an inner member made of unidirectional material for providing strength. This segmentation allows each component to fulfill its specific function without compromise
Solution Approach 2:
The inner member (unidirectional material) is placed inside the outer member (woven fabric), creating a nested structure where the stronger but less flexible material is protected by and integrated with the more flexible outer material, enabling both complex shaping and strength enhancement
2Strength
If a composite material with high strength is formed using traditional lamination, then the internal strength increases, but the ease of manufacture for complex shapes decreases
Solution Approach 1:
By separating the structural function (strength) from the forming function (shape), the invention allows the outer woven fabric to be easily formed into complex shapes while the inner unidirectional material provides the required strength, significantly improving ease of manufacture for complex geometries
Solution Approach 2:
The invention applies different material properties to different locations: the outer surface uses woven fabric suitable for complex shaping, while the inner core uses unidirectional material optimized for strength, allowing each region to have the quality needed for its specific function
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
Enables the realization of desired shapes while inhibiting a decrease in strength, improving internal strength and allowing for more complex geometries in composite materials.
Implementation Method 1
a composite material forming step of forming a composite material in which the outer member and the inner member are joined to each other by curing the resin of the inner member to join the outer member and the inner member to each other
Implementation Method 2
the thermoplastic resin included in the outer member is melted and cured to join the outer member and the inner member to each other
Data Source
AI summary
A desired shape can be easily realized, and a decrease in strength can be inhibited. A method for producing a composite material includes: an insertion step of inserting an inner member in which a second reinforcing fiber is impregnated with a resin into a space of an outer member that is formed of a woven first reinforcing fiber extending in an undulating manner, the outer member including an opening that is provided at at least one end portion and the space that communicates with the opening; and a composite material forming step of forming a composite material in which the outer member and the inner member are joined to each other by curing the resin of the inner member to join the outer member and the inner member to each other.