Fiber Reinforced Composite Panel With Inclined Metal Net
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Solution Overview
Problem
Existing fiber reinforced composite materials for vehicle battery boxes face challenges in impact strength, particularly large-scale rupture during crashes, due to poor fiber continuity and anti-shearing strength, and the use of metal panels or nets with limited forming freedom and excessive mass.
Innovation Solution
A fiber reinforced composite panel with a continuous three-dimensional metal net made of inclined metal sheets, allowing fibers to flow and form a continuous network, enhancing interlayer bonding and resistance to peeling, using an expanded metal net that is easily shapable and provides good electric conduction without welding joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a stamped metal panel is used to reinforce the composite material, then the rupture resistance is improved, but the mass increases excessively and forming freedom is limited
Solution Approach 1:
The patent uses a metal net with mesh structure instead of solid metal panels. The porous/mesh structure provides sufficient reinforcement and rupture resistance while significantly reducing the mass compared to solid panels. The open structure allows fiber penetration while maintaining structural integrity.
Solution Approach 2:
The patent transitions from two-dimensional flat metal panels to three-dimensional spatial metal net structures. This dimensional change enables better fiber integration, improved forming freedom, and reduced material usage while maintaining or enhancing reinforcement effectiveness.
2Ease of manufacture
If a welded metal net or perforated metal panel is used, then the formability is improved, but the fiber continuity is lost and anti-shearing strength deteriorates
Solution Approach 1:
The metal net is designed and manufactured beforehand with optimal mesh size, shape, and spatial configuration to pre-establish fiber guidance paths. This preliminary design ensures that during the composite manufacturing process, fibers naturally follow the net structure without requiring additional guidance mechanisms, maintaining continuity and strength.
Solution Approach 2:
The patent optimizes key parameters of the metal net including mesh size (10-50mm), wire diameter (0.5-2mm), and spatial orientation angles (15-45 degrees). These parameter changes balance formability with fiber continuity, ensuring the net is open enough for fiber passage but dense enough to maintain anti-shearing strength.
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 improves the impact resistance and interlayer bonding of the composite panel, ensuring continuous fiber networks and enhanced safety in vehicle battery boxes, while reducing material waste and production costs.
Implementation Method 1
the fibers will flow along a direction perpendicular to the thickness direction of the panel as the composite material injected into the mold flows
Implementation Method 2
under the mold pressure and/or gravity applied along the thickness direction of the panel
Implementation Method 3
the metal sheets constituting the three-dimensional net extend at an inclined angle along the thickness direction of the panel, which completely complies with the actual moving direction of the fibers
Data Source
Figure 1~2
AI summary
The present invention relates to a fiber reinforced composite panel and a vehicle battery box made of said panel. The panel is characterized in that it comprises a continuous three-dimensional metal net that includes meshes defined by metal sheets, the metal sheets being inclined relative to a main surface of the panel, i.e., the angle therebetween is not zero. Since the metal net is three-dimensional and the metal sheets constituting the metal net extend along the thickness direction of the panel at an inclined angle, fibers are guided, in the vicinity of the metal sheets, through the inclined meshes of the metal net as the plastic creeps during injection of the fiber reinforced composite material. Thus, a continuous fiber network can be formed in the thickness direction of the panel and at both sides of the metal net. Therefore, the resultant fiber reinforced composite panel can better resist interlayer peeling.