Fiber-Reinforced Composite Layer Bonding via Resin Penetration
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Solution Overview
Problem
Fiber-reinforced composite materials with randomly arranged reinforcement fibers have low mechanical strength and stiffness, leading to potential damage under local loads, as the adhesion strength at the interface between composite layers is insufficient, causing separation under stress.
Innovation Solution
A fiber-reinforced composite material is created by bonding a first composite material layer with a fibrous substrate of crosswise reinforcement fiber bundles and a second composite material layer with randomly arranged reinforcement fibers, where the second fibers and thermoplastic resin enter into bores on the surface of the first layer, enhancing adhesion and preventing separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reinforcement fibers are arranged randomly in composite material, then moldability is improved and compact can be made in complicated shape easily, but mechanical strength and stiffness are reduced
Solution Approach 1:
The composite material is segmented into multiple layers with different fiber arrangements. The first layer has randomly arranged fibers for good moldability, while the second layer has woven fibrous substrate for high strength. This segmentation allows each layer to fulfill its specific function without compromising the overall performance.
Solution Approach 2:
The invention uses a composite structure combining two types of fiber-reinforced composite material layers. The first layer uses randomly arranged reinforcement fibers, while the second layer uses a woven fibrous substrate, creating a multi-layer composite that integrates the advantages of both configurations.
2Strength
If woven fibrous substrate is used to increase mechanical strength, then strength is improved, but moldability is reduced compared to random fiber arrangement
Solution Approach 1:
The composite material is segmented into multiple layers with different fiber arrangements. The first layer has randomly arranged fibers for good moldability, while the second layer has woven fibrous substrate for high strength. This segmentation allows each layer to fulfill its specific function without compromising the overall performance.
Solution Approach 2:
The invention uses a composite structure combining two types of fiber-reinforced composite material layers. The first layer uses randomly arranged reinforcement fibers, while the second layer uses a woven fibrous substrate, creating a multi-layer composite that integrates the advantages of both configurations.
3Ease of manufacture
If first composite material layer and second composite material layer are bonded via thermoplastic resins, then bonding is achieved, but adhesion strength at interface is insufficient and layers separate under stress
Solution Approach 1:
The woven fibrous substrate in the second layer is designed with a porous structure having through-holes. This porous structure allows thermoplastic resin to penetrate and form mechanical interlocking, significantly enhancing the adhesion strength at the interface between layers while maintaining bonding capability.
Solution Approach 2:
The thermoplastic resin penetrates into the through-holes of the porous woven substrate, creating a nested structure where the resin is embedded within the porous network. This nesting effect provides mechanical interlocking that strengthens the interface bonding between layers.
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 anchor effect of the second fibers and resin within the bores increases the adhesiveness and strength between the composite layers, improving the mechanical properties and preventing separation under stress, thereby enhancing the overall performance of the composite material.
Implementation Method 1
the second reinforcement fibers and the second thermoplastic resin enter into the bores
Implementation Method 2
at least the second thermoplastic resin is softened so that the second reinforcement fibers and the second thermoplastic resin enter into the bores
Data Source
AI summary
A fiber-reinforced composite material for increasing adhesive strength between a first composite material layer including a fibrous substrate with reinforcement fiber bundles arranged crosswise, and a second composite material layer including second reinforcement fibers arranged randomly. The first composite material layer including a fibrous substrate having reinforcement fiber bundles crossing and being drawn and aligned first reinforcement fibers; and first thermoplastic resin, with at least each of the reinforcement fiber bundles is impregnated; and a second composite material layer including second reinforcement fibers arranged randomly in second thermoplastic resin. The first composite material layer and the second composite material layer bonded to each other. The first composite material layer has bores on at least a surface thereof that is to be bonded with the second composite material layer. The second reinforcement fibers and the second thermoplastic resin enter into the bores.