Multi-Angle Composite Laminate for Balanced Tape Winding Pipes
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Solution Overview
Problem
Resin impregnated fiber reinforced molded articles face challenges in controlling shape during melt press molding due to anisotropy in fiber orientation, leading to non-uniform melt flow and potential reduction in mechanical strength, and tape winding pipes often have an imbalance between bending and compressive rigidity.
Innovation Solution
A laminate structure with five or more layers of unidirectionally oriented resin impregnated fiber reinforced composition layers, where the orientation angles of each layer follow specific relationships to achieve symmetric planes and a balanced rigidity in tape winding pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If unidirectionally aligned reinforcing fibers are used to improve strength, then mechanical strength is improved, but anisotropy of strength becomes dominant and applicable types of practical products are limited
Solution Approach 1:
The laminate is divided into multiple layers with different fiber orientation angles (0°, 28° to 42°, 83° to 97°, -28° to -42°, -2° to 2°). Each layer contributes to strength in different directions, collectively providing omnidirectional strength while maintaining product versatility.
Solution Approach 2:
The invention creates a composite laminate structure combining multiple resin impregnated fiber reinforced sheets with specific orientation relationships. This composite approach achieves both high strength and broad applicability by integrating different orientation layers that complement each other's mechanical properties.
2Strength
If unidirectionally aligned reinforcing fibers are used to improve strength, then mechanical strength is improved, but control of moldability and molded appearance becomes difficult
Solution Approach 1:
The laminate structure segments the fiber reinforcement into multiple orientation layers, which distributes and balances the anisotropic effects during molding. This segmentation allows the mold to receive more uniform stress distribution, improving moldability and appearance control.
Solution Approach 2:
The invention changes the orientation angle parameters of successive layers according to specific relationships. This parameter optimization ensures that during melt press molding, the combined effect of all layers achieves uniform shrinkage and stress distribution, improving molded appearance and dimensional control.
3Productivity
If resin impregnated fiber reinforced sheets are laminated and melt press molded, then productivity is improved, but non-uniform melt flow occurs due to fiber orientation causing shape control issues
Solution Approach 1:
The laminate is segmented into layers with specifically related orientation angles. This segmentation creates a self-balancing structure where the melt flow resistance from different layers compensates for each other, achieving uniform overall flow and shape retention during high-speed melt press molding.
Solution Approach 2:
The composite laminate structure combines multiple fiber orientations to create a material that maintains shape fidelity during processing. The specific orientation relationships ensure that the composite behaves more isotropically during molding, enabling productivity improvement without shape control loss.
4Ease of manufacture
If conventional tape winding pipe structures are used, then manufacturing is simplified, but balance between bending rigidity and compressive rigidity becomes poor
Solution Approach 1:
The pipe structure is segmented into multiple layers with specific orientation angles (60° to 85°, -85° to -60°, 0° to 40°, -40° to 0°). This segmentation allows each layer to contribute differently to bending and compressive resistance, achieving balanced rigidity while maintaining manufacturing simplicity through standardized winding angles.
Solution Approach 2:
The invention creates a composite pipe structure with multiple fiber orientations that simultaneously provides bending and compressive rigidity. The specific angle relationships ensure that the composite structure achieves balanced mechanical properties without complicating the manufacturing process.
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 laminate structure allows for controlled shape retention during molding without a mold and achieves a balance between bending and compressive rigidity in tape winding pipes, enhancing mechanical properties and surface characteristics.
Implementation Method 1
When a thermoplastic resin is used as a resin component of the resin impregnated fiber reinforced molded article
Data Source
AI summary
Disclosed are a laminate having a laminated structure of five or more layers wherein each layer is a resin impregnated fiber reinforced composition layer in which fibers are oriented unidirectionally, the resin in the resin impregnated fiber reinforced composition layer is an olefin-based polymer having the melting point or the glass-transition temperature of 50 to 300°C, and the shape of the laminate can be easily controlled by melt press molding; and a tape winding pipe excellent in balance between bending rigidity and compressive rigidity.