Fiber Composite Intermediate Layer Termination for Embedding Strength
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Solution Overview
Problem
Current methods for joining multi-layer fiber composite components, such as mechanical joining techniques, result in reduced embedding strength and increased mass due to structural thickening, limiting the use of cost-effective injection technologies for large-scale structures.
Innovation Solution
A fiber composite component design where fiber layers and intermediate layers are embedded in a resin matrix with specific termination edges and thickness ratios, allowing for improved embedding properties and constant component thickness, while also enabling the use of wet processes for production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical joining techniques with bolt connections are used to join multi-layer fiber composite components, then connection safety is improved, but embedding strength is reduced and mass increases due to structural thickening
Solution Approach 1:
The intermediate layer is segmented into multiple thin layers (first intermediate layer, second intermediate layer, third intermediate layer) with different orientations and functions. This segmentation allows each layer to serve specific purposes: the first layer provides embedding reinforcement, the second layer offers structural support, and the third layer enables resin flow channels, collectively solving the embedding strength problem without requiring structural thickening
Solution Approach 2:
The intermediate layers are positioned locally at the connection region where embedding strength is needed, rather than uniformly throughout the entire component. This local quality approach reinforces the connection area specifically while maintaining constant component thickness elsewhere, preventing mass increase
2Strength
If intermediate layers are integrated to improve connection quality, then embedding strength is improved, but component mass increases due to structural thickening
Solution Approach 1:
Instead of increasing thickness in the vertical dimension, the solution uses the lateral dimension by creating resin flow channels that extend laterally through the intermediate layers. The channels are formed by positioning reinforcement elements at specific lateral positions, allowing resin to flow along the main surface rather than requiring vertical thickening for reinforcement
3Strength
If flat intermediate layers are used for reinforcement, then connection quality is improved, but injection technologies cannot be used due to barrier effects on resin flow
Solution Approach 1:
The intermediate layers are designed with a porous structure containing resin flow channels that allow matrix resin to penetrate and flow through them. The channels are formed by positioning reinforcement elements that create void spaces, transforming the intermediate layers from solid barriers into permeable structures that facilitate resin infusion while maintaining reinforcement functionality
Solution Approach 2:
The reinforcement elements serve as intermediaries that perform dual functions: they provide structural reinforcement while simultaneously creating resin flow channels. These elements act as mediators between the conflicting requirements of reinforcement and resin flow, allowing both functions to coexist within the same intermediate layer structure
Data Source
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Figure 5~6
AI summary
In a fiber composite component (1), several fiber layers (4) and several interlayers (5) are embedded in a resin matrix (6) in a region (2) extending along a main surface 3. A first fiber layer (7) terminates in the region (2) with a fiber layer termination edge (9) between two continuous fiber layers (4). A first interlayer (13), coming from the opposite direction, terminates within the region (2) with an interlayer termination edge (11) running parallel to the first fiber layer termination edge between the same fiber layers (4). At least one further interlayer (14) terminates between fiber layers between which neither one of the fiber layers (4) nor one of the interlayers (5) terminates in the region (2), and the mean interlayer thickness of the interlayers (5) terminating in the region (2) is at most half the mean fiber layer thickness of the fiber layers (4) terminating in the region (2).