Composite Load-Bearing Member with Helical Fiber Shell

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing composite structural members, such as tubes and sandwich structures, lack certain mechanical properties required for specific applications, necessitating the development of alternative structural members with enhanced strength and loading capabilities.

Innovation Solution

A composite load-bearing member comprising a solid core with a shell bonded on all sides, featuring first reinforcing fibers parallel to the longitudinal axis and second reinforcing fibers oriented obliquely, which are helically wrapped around the core, along with shear reinforcement panels to enhance shear and bending resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional tubes or sandwich structures are used, then the structure is lightweight, but the mechanical properties (shear and bending resistance) are insufficient for specific applications

Engineering Contradiction:
Improveshear and bending resistanceVSAvoidstructural complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The patent employs composite materials consisting of a core structure combined with a shell containing both longitudinal and oblique reinforcing fibers. This composite construction provides enhanced shear and bending resistance while maintaining structural efficiency, directly resolving the contradiction between strength requirements and structural complexity.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by orienting reinforcing fibers in specific directions (longitudinal and oblique) at different locations within the shell. The longitudinal fibers provide strength along the member axis, while oblique fibers enhance shear resistance, creating locally optimized reinforcement patterns that address specific mechanical property requirements without uniformly increasing overall complexity.

Inventive Principle:
Principle #3Local quality

2Strength

If additional reinforcing fibers are added to improve mechanical properties, then strength increases, but manufacturing complexity increases

Engineering Contradiction:
Improvemechanical propertiesVSAvoidmanufacturing complexity
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The patent introduces oblique fibers at angles to the longitudinal axis, adding a dimensional aspect to the fiber reinforcement. This oblique orientation creates a three-dimensional reinforcement pattern within the shell that enhances mechanical properties while maintaining a relatively simple manufacturing approach through wrapped construction methods.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The oblique reinforcing fibers are wrapped in a helical or curved pattern around the core, creating a continuous curved reinforcement path. This wrapping approach simplifies manufacturing compared to laying individual straight fibers, as the continuous wrap can be applied in a single operational pass while still providing enhanced mechanical properties through the oblique fiber orientation.

Inventive Principle:
Principle #14Spheroidality (Curvature)

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 solution provides improved mechanical properties, including increased shear and bending resistance, making it suitable for applications like railway transoms that require 4-point loading and fastener integration, while maintaining a lightweight and strong structure.

Implementation Method 1

a shell that is bonded to the core on at least the upper, lower and lateral sides and that includes first reinforcing fibres and second reinforcing fibres in a first resin matrix

Methodology Applied
Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20240368888A1Structural Member and Method of Producing a Structural Member
Publication Date: 2024.11.07 AUSTRAK
  • US20240368888A1 patent drawing
  • US20240368888A1 patent drawing
  • US20240368888A1 patent drawing

AI summary

A composite load-bearing member is disclosed. The member includes a core with opposed upper and lower side and opposed lateral sides extending between the upper and lower side and opposed ends extending between the upper and lower sides and between the lateral sides and with a longitudinal axis extending through the ends. The core is substantially solid. The member further includes a shell that is bonded to the core on at least the upper, lower and lateral sides and that includes first reinforcing fibres and second reinforcing fibres in a first resin matrix. The first reinforcing fibres are parallel to the longitudinal axis and the second reinforcing fibres are oblique to the longitudinal axis. Also disclosed is a method of forming the composite load-bearing member.