Fiber Reinforced Composite Warp Yarn Diameter Gradient
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Solution Overview
Problem
Fiber-reinforced composites with thickness changes suffer from reduced strength due to resin-rich portions formed at stepped thickness variations, where the ends of fiber layers are displaced, leading to uneven matrix resin distribution.
Innovation Solution
A fiber-reinforced composite is created using a fabric laminate with warp and weft yarns, where the diameter of warp yarns gradually changes to form an inclined portion, eliminating the need for end displacement and ensuring continuous thickness change without resin-rich areas, using a special yarn manufacturing apparatus to produce diameter-changing portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the fiber layers are laminated with the ends displaced relative to each other to change thickness gradually, then the thickness can be varied, but resin-rich portions are formed reducing the strength
Solution Approach 1:
The patent applies local quality by varying the number of fabric layers at different locations to achieve gradual thickness change. Specifically, the reinforcing base material comprises a first region with a first number of layers and a second region with a second number of layers different from the first, creating a gradient structure that eliminates abrupt thickness transitions and prevents resin-rich portions.
Solution Approach 2:
The patent segments the reinforcing base material into multiple fabric layers that can be independently arranged. By dividing the structure into multiple layers with different quantities in different regions, the patent achieves continuous thickness variation without forming stepped portions, thereby maintaining structural strength.
2Shape
If multiple fiber layers are laminated to achieve thickness change, then the thickness can be adjusted, but the number of fiber layers changes creating stepped portions
Solution Approach 1:
The patent implements local quality by designing different regions with different numbers of fabric layers. The first region has a first number of layers while the second region has a second number of layers, creating a controlled gradient that achieves thickness variation while maintaining uniform fiber distribution within each region and avoiding stepped transitions.
Data Source
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AI summary
A fabric laminate used as a reinforcing base material of a fiber-reinforced composite is constituted by laminating fabrics having warp yarns and weft yarns. Each warp yarn has a diameter-changing portion, in which the diameter of the yarn gradually changes in the yarn longitudinal direction in the vicinity of one end in the yarn longitudinal direction of the warp yarn.