Composite Product with Partially Embedded Fibers
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Solution Overview
Problem
Traditional composite products made from fiber-reinforced materials are labor-intensive and expensive, with issues such as fiber distortion due to resin flow and pressurization, and difficulties in integrating add-on parts, painting, and recycling, while also being prone to thermal expansion problems.
Innovation Solution
A composite product is created using a first layer of plastic, a support structure, and a layer of fibers, where the fibers are not fully embedded in the matrix, allowing for reduced thermal expansion and improved optical appearance, with the plastic penetrating the fibers to restrict movement and provide mechanical interconnection, and the use of a second layer of plastic or other materials for additional support and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fibers are fully embedded in the matrix using traditional composite manufacturing methods, then mechanical strength and structural integrity are improved, but thermal expansion increases and manufacturing cost increases
Solution Approach 1:
The patent applies local quality by creating different bonding characteristics in different regions of the composite. The matrix material is selectively bonded to fibers in certain areas while leaving other areas unbonded, allowing localized mechanical strength where needed while reducing overall thermal expansion through unbonded regions. This differential bonding approach enables the composite to maintain structural integrity while mitigating thermal expansion effects.
2Strength
If traditional fiber-reinforced composite manufacturing methods are used, then mechanical properties are improved, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent extracts the bonding function from the traditional composite manufacturing process. Instead of fully embedding fibers in the matrix through complex resin infusion and pressurization processes, the invention selectively bonds the matrix to fibers only in specific regions, leaving other regions unbonded. This extraction of the bonding function simplifies manufacturing while maintaining necessary mechanical properties.
3Stability of the object's composition
If traditional composite manufacturing processes are used, then structural integrity is improved, but recyclability deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the composite structure into bonded and unbonded regions. The unbonded regions act as separation zones that allow the composite to be easily disassembled and recycled. This segmented approach maintains structural integrity in bonded areas while enabling straightforward separation and recycling through unbonded areas, eliminating the need for complex de-bonding processes.
4Strength
If fibers are fully embedded in matrix with strong adhesion, then mechanical interconnection is improved, but optical appearance deteriorates
Solution Approach 1:
The patent applies local quality by creating spatially varying bonding characteristics. Certain regions of the composite have strong matrix-fiber bonding for mechanical strength, while other regions have reduced or no bonding to allow fiber visibility and optimal optical appearance. This local differentiation enables the composite to simultaneously achieve mechanical interconnection where needed and aesthetic appearance where visible.
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 method results in a cost-effective, flexible, and durable composite product with improved optical appearance and reduced thermal expansion, while being easily recyclable, and allows for the use of fewer labor-intensive processes.
Implementation Method 1
The fabric layers and plastic layer are heated and pressed at a pressure greater than atmospheric pressure, during which the plastic layer is at least partially melted
Implementation Method 2
After reaching the desired final form, the partially-melted plastic is cooled, thereby bonding the fabric layers to one another
Data Source
AI summary
The invention is directed to a composite product that includes a first layer made from a plastic and a support structure and a layer of fibers arranged between the first layer of plastic and the support structure. The first layer of plastic penetrates the layer of fibers at least at certain locations such that the first layer of plastic is mechanically interconnected with the layer of fibers.