Composite Sheet Core End Wall Fiber Alignment
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Solution Overview
Problem
Existing composite materials with open-ended cellular cores and randomly oriented fibers often fail to optimize strength and weight due to fiber deflection and buckling under bending forces, leading to inefficient load carrying and increased weight when trying to enhance strength.
Innovation Solution
A composite design featuring an open-ended core with continuous fibers oriented along its end walls, secured using methods like adhesive or heat, and impregnated with resin to form a skin that aligns with the core's bi-axial pattern, enhancing structural strength while minimizing unnecessary fiber placement and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fibers are randomly oriented over the core, then fiber placement is simple, but fiber deflection and buckling occur under bending forces reducing strength
Solution Approach 1:
The patent applies local quality by orienting fibers specifically along the end walls of the core structure where bending stresses concentrate, rather than uniform random orientation. This localized fiber placement at critical stress points prevents fiber deflection and buckling while maintaining structural strength, addressing the contradiction between simplicity and strength enhancement.
2Strength
If more fibers or more resin are added to increase strength, then composite strength increases, but weight increases
Solution Approach 1:
The patent extracts and removes unnecessary fibers from non-critical areas, retaining only the essential fiber placement along the end walls. This selective removal eliminates redundant material that would add weight without contributing to strength, thereby resolving the contradiction between increasing strength and minimizing weight.
Solution Approach 2:
By concentrating fibers only where structurally necessary (along end walls), the patent achieves maximum strength with minimum material usage. This localized approach prevents weight increase from unnecessary fiber addition while maintaining enhanced strength at critical locations.
3Weight of moving object
If the core and wall spacing are made wide and skin thickness is reduced, then weight decreases, but fiber deflection and buckling increase under load
Solution Approach 1:
The patent applies local quality by placing continuous fibers specifically along the end walls of the spaced core structure. This localized reinforcement provides critical support at the points where fiber deflection and buckling would otherwise occur, maintaining load carrying reliability even with wide spacing and reduced skin thickness.
Solution Approach 2:
The fibers are positioned in advance along the end walls before final composite formation, creating pre-positioned reinforcement that proactively prevents fiber deflection and buckling under future loads. This preliminary placement ensures structural reliability is maintained despite reduced material quantity.
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
This design significantly improves the composite's strength and weight efficiency by aligning continuous fibers with the core's end walls, reducing fiber wastage and enhancing load-carrying capacity without increasing weight, making it suitable for applications like vehicle and aircraft components.
Implementation Method 1
The at least one continuous fiber is oriented along the at least one end wall of the core and is secured to the core
Implementation Method 2
The fibers or fiber mat may be secured to the core using a variety of methods such as heat from the molding process, added heat, or an adhesive
Data Source
AI summary
A composite sheet and a method of making a composite sheet. A core having end walls is provided. Continuous fibers or a continuous fiber mat is secured to the core such that the continuous fibers align with the end walls of the core.