Dual Layer Composite Vehicle Panels Using Epoxy Glass and Carbon Fibers
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Solution Overview
Problem
Current glass-filled resins are unable to meet the requirements for ever-lighter, yet strong vehicle panel articles due to limitations in tensile strength and modulus, and carbon fiber filled resins are costly with reduced surface gloss.
Innovation Solution
A dual layer composite article is formed using a process that incorporates a mixed fiber source of epoxy coated glass fibers and carbon fibers, with a high primary fiber:carbon fiber ratio in the outer layer and a lower ratio in the inner layer, allowing for a strong and lightweight structure with improved surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If glass fiber filled resins are used to reduce weight, then density is reduced, but tensile strength and modulus are insufficient
Solution Approach 1:
The patent uses a composite fiber system combining glass fibers and carbon fibers in a resin matrix. The glass fiber provides density reduction while the carbon fiber reinforcement restores and enhances tensile strength and modulus, creating a synergistic composite material that achieves both lightweight and high-strength properties simultaneously.
2Strength
If carbon fiber filled resins are used to improve tensile strength and reduce density, then strength and weight performance improve, but material cost increases
Solution Approach 1:
The patent applies different fiber types to different regions or functions within the composite structure. Carbon fiber is strategically used in regions requiring high strength and stiffness, while glass fiber is used in regions where cost reduction is prioritized. This localized fiber placement optimizes both performance and cost effectiveness.
Solution Approach 2:
By creating a composite fiber system that combines expensive carbon fibers with cheaper glass fibers, the patent achieves cost-effectiveness. The glass fiber serves as a cost-effective base material while carbon fiber provides targeted strength enhancement, reducing overall material cost compared to using carbon fiber throughout.
3Strength
If carbon fiber filled resins are used to achieve high strength, then tensile strength improves, but surface gloss deteriorates
Solution Approach 1:
The patent places glass fibers, which provide excellent surface gloss and finish, in the outer surface layers of the composite article. Carbon fiber is positioned in inner layers where strength is critical but surface appearance is less important. This stratification allows the surface to achieve high gloss while internal layers provide structural 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 process achieves high tensile strength and reduced weight in vehicle panels, with a surface finish comparable to glass fiber articles and the strength of carbon fiber articles, while maintaining a lower material cost.
Implementation Method 1
a process for molding with a non-oriented epoxy coated chopped glass fiber tow that bonds to a thermoset matrix
Data Source
AI summary
A process is provided for molding a resin matrix around a distribution of well distributed epoxy coated glass fibers to produce an article. The article is mass produced by the molding process based on a one or more layer structure, with an outer panel having a high degree of surface smoothness common to automotive body panels and a comparatively high tensile strength joinder thereto. The epoxy coated glass fibers are present in a single panel of an article or all such panels of a multiple layer article. The epoxy coated glass fibers can be present in an articles in a form of: chopped glass fibers that are intermixed and vary in orientation, a woven roving containing predominately epoxy glass fibers with carbon fibers dispersed there through, or non-woven fiber mats.