Fiber Reinforced Foam With Structured Surfaces
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Solution Overview
Problem
Existing methods for producing fiber/foam composite materials often result in insufficient mechanical stability, particularly for components requiring lightness and high strength, as they typically involve planar reinforcement layers that do not provide optimal amplification in three spatial directions, leading to complex and costly processes.
Innovation Solution
A method involving a first foam body with a structured surface and a first fiber material applied to create an intermediate product with a structured fiber surface, followed by a second foam body with an inverse structured surface, which is then connected to achieve a fiber/foam composite material with enhanced three-dimensional reinforcement, reducing material loss and processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If planar reinforcement layers are used in fiber/foam composites, then the manufacturing process is simple, but the mechanical properties in three spatial directions are insufficient
Solution Approach 1:
The patent transitions from planar (2D) reinforcement layers to three-dimensional (3D) structured surfaces with fiber materials. The structured surfaces include protrusions and recesses that extend in multiple spatial directions, providing reinforcement not just in the plane of the foam but also through the thickness direction, achieving optimal reinforcement in all three spatial directions.
Solution Approach 2:
The patent combines foam materials with fiber materials in a composite structure where the fiber material is applied to structured surfaces of the foam. This creates a hybrid composite that leverages the lightweight properties of foam and the strength properties of fibers in a three-dimensional configuration, achieving both lightness and high mechanical stability.
2Strength
If trigonally prismatic foam bodies are used for three-dimensional reinforcement, then mechanical properties improve, but the manufacturing process becomes extremely time-consuming and expensive
Solution Approach 1:
The patent divides the complex task of creating three-dimensional reinforcement into simpler segments: first, standard foam bodies with planar surfaces are manufactured (simple step), then structured surfaces are created on these foam bodies (second step), and finally fiber materials are applied to these structured surfaces (third step). This segmentation avoids the need to manufacture complex trigonally prismatic foam bodies as single pieces, significantly reducing manufacturing complexity and cost.
Solution Approach 2:
The patent performs preliminary actions by first creating the foam bodies with planar surfaces using standard, simple manufacturing processes, then subsequently adding the structured surfaces and fiber reinforcement. This approach allows the base foam structure to be prepared in advance using efficient processes, and the complex reinforcement features to be added later, avoiding the need to manufacture the entire complex structure in one time-consuming operation.
3Strength
If complex manufacturing processes with multiple steps are used, then three-dimensional reinforcement is achieved, but production costs increase
Solution Approach 1:
The patent merges multiple functions into a unified process flow: the structured surfaces are created directly on the foam bodies using processes that can be integrated with foam manufacturing, and the fiber material application is performed in a continuous manner on these structured surfaces. This merging of steps eliminates the need for separate, complex manufacturing stages required by prior art methods, reducing overall production costs while achieving three-dimensional reinforcement.
Data Source
Figure 1A~1C
Figure 1D~3
AI summary
The invention relates to a method for producing a fiber/foam composite material (FSV1), in which a first fiber material (FM1) is applied to a first foam material body (SK1), obtaining a first structured fiber surface (F01), on which a second foam material body (SK2) is then applied, obtaining the fiber/foam composite material (FSV1).