Continuous-Fiber Reinforced Structural Component for Tensile and Impact Loads
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Solution Overview
Problem
Existing structural components face challenges in effectively resisting tensile loading and impact resistance, particularly in terms of weight and cost, as conventional materials like steel, aluminum, and carbon fiber may not provide optimal solutions.
Innovation Solution
A reinforced structural component is developed using a combination of thermoplastic or thermoset plastic material with chopped fibers and continuous fibers, configured to withstand tension and impact, featuring a body portion with a central longitudinal axis and cross-sectional layers of continuous fibers disposed parallel to a secondary axis, allowing for resistance against tensile forces and impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional materials like steel, aluminum, or carbon fiber are used to resist tensile loading, then strength is improved, but weight increases
Solution Approach 1:
The patent employs a composite material system consisting of a plastic matrix (thermoplastic or thermoset) reinforced with chopped fibers and continuous fibers. This composite structure provides high tensile strength while maintaining lower weight compared to conventional steel or aluminum, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent strategically places continuous fibers in specific longitudinal segments where tensile stresses are highest, rather than uniformly distributing reinforcement throughout the entire component. This localized reinforcement approach optimizes strength-to-weight ratio by concentrating material where it is most needed.
2Strength
If conventional materials like steel or aluminum are used to provide impact resistance, then strength is improved, but cost increases
Solution Approach 1:
The combination of plastic matrix with chopped and continuous fibers creates a cost-effective composite material that provides impact resistance without the high material costs associated with steel or aluminum. The plastic matrix itself offers good impact toughness, while the fiber reinforcement enhances this property.
Solution Approach 2:
The patent utilizes thermoplastic materials that can be processed using conventional molding techniques, and thermoset materials that cure to provide enhanced impact resistance. By selecting appropriate plastic matrices and fiber combinations, the patent achieves impact resistance at lower cost points compared to conventional metals.
3Strength
If continuous fiber layers are added to resist tension, then tensile strength is improved, but device complexity increases
Solution Approach 1:
The patent places continuous fiber layers only in specific longitudinal segments where tensile stresses occur, rather than throughout the entire component. This selective placement reduces the overall complexity of the structure while maintaining tensile strength where needed.
Solution Approach 2:
The continuous fiber reinforcement is divided into discrete longitudinal segments rather than forming a continuous layer throughout the entire component. This segmentation allows for simpler manufacturing and assembly while providing tensile strength in the critical regions.
Data Source
AI summary
A reinforced structural component includes a body portion made of a combination of plastic material and chopped fibers. The body portion has a central longitudinal axis and a cross-section orthogonal to the central longitudinal axis, with the cross-section having an outer periphery and an inner core inward of the outer periphery. The body portion has an outer peripheral portion and an inner core portion corresponding to respective longitudinal projections of the outer periphery and inner core. The body portion is configured for being acted upon by a combination of forces causing tension within one or more longitudinal segments of the inner core portion. The reinforced structural component also includes one or more layers of continuous fiber disposed longitudinally within the one or more longitudinal segments, so as to resist tension caused within the one or more longitudinal segments.