Fiber Composite Laminate with Decoupled Dry Layer for Impact Resistance
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Solution Overview
Problem
Fiber-composite laminates for motor vehicle body components are prone to fractures and delamination under high force, leading to splinter formation and reduced structural integrity, which is not adequately addressed by existing solutions that focus on ductile layers for impact absorption.
Innovation Solution
A planar body component featuring a cured main laminate of fiber-reinforced plastics with an adhesively bonded, non-ductile dry woven fibrous layer that decouples from the main laminate upon force application, utilizing a low-shear linkage and a thermoplastic or thermosetting matrix to enhance deformation capability and prevent splintering, with the fibrous layer oriented to direct force away from the vehicle interior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a fiber-reinforced plastics laminate is used for body components, then weight is reduced compared to steel or aluminum, but the structure becomes prone to fractures and delamination under high force
Solution Approach 1:
The patent employs a composite structure consisting of a fiber-reinforced plastics main laminate combined with an additional fibrous layer (such as textile or non-woven fabric). This multi-material composite approach leverages the high strength-to-weight ratio of fiber-reinforced plastics while the additional fibrous layer provides ductility and fracture resistance, thereby maintaining weight advantages while improving structural reliability under high force conditions.
Solution Approach 2:
The additional fibrous layer is selectively applied to specific regions of the main laminate where fracture resistance and splinter prevention are most critical. This localized reinforcement strategy allows the component to maintain overall lightweight construction while providing enhanced structural integrity and damage tolerance at key stress points and impact zones.
2Strength
If carbon fiber laminate is used to reduce weight, then the material strength increases, but the material becomes insufficiently ductile and prone to fracture formation
Solution Approach 1:
The patent combines rigid fiber-reinforced plastics material with a more ductile additional fibrous layer (textile or non-woven fabric). The fiber-reinforced plastics provides high strength and stiffness, while the additional fibrous layer contributes ductility and the ability to deform plastically. This composite material system achieves both high strength and adequate ductility, preventing catastrophic fracture formation while maintaining structural integrity.
3Object-affected harmful factors
If additional elastic layers are applied to absorb impact, then impact energy is absorbed, but the layers do not contribute toward structural integrity of the component
Solution Approach 1:
The patent uses an additional fibrous layer made from textile or non-woven fabric that inherently provides both impact absorption capability and structural reinforcement. Unlike purely elastic protective layers, this fibrous layer is integrated into the laminate structure and contributes to overall structural integrity while simultaneously absorbing impact energy and preventing splinter formation through its ductile deformation characteristics.
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 solution significantly increases deformation capability and prevents splinter formation by allowing individual fibers to slide and move relative to the main laminate, maintaining structural integrity while reducing the risk of splintering and improving weight efficiency compared to steel or aluminum structures.
Implementation Method 1
an additional fibrous layer (2) that is adhesively bonded to the main laminate (1)
Implementation Method 2
the progression of the fracture by virtue of the textile structure takes place at a significantly higher resistance
Implementation Method 3
enables individual fibers of the woven fabric to slide to the impact point
Data Source
AI summary
A planar body component for motor vehicles is designed as a fiber composite laminate having a cured main laminate of fiber-reinforced plastic and an additional fiber layer, which is glued to the main laminate and can be decoupled from the main laminate in some sections when force is applied to the planar body component. The additional fiber layer is formed of a non-ductile, dry fiber textile.