Fiber-Reinforced Sheet Laminate Slit Layout for Complex Forming
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Solution Overview
Problem
Existing methods for manufacturing fiber-reinforced sheet laminates face issues such as fiber curling, separation, and uneven fiber lengths leading to strength reduction and reduced shaping-ability when forming complex shapes due to differences in peripheral lengths during bending.
Innovation Solution
A fiber-reinforced sheet laminate design where multiple fiber-reinforced sheets with fibers in different directions are laminated and slits are formed to ensure equal fiber lengths, with slits overlapping when viewed from the lamination direction, allowing for uniform fiber cutting and improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If continuous long slits are formed in a multi-stack material to cut fibers, then shaping-ability is improved, but fiber-reinforced sheets may curl up or separate from each other
Solution Approach 1:
The patent divides the continuous long slits into multiple intermittent slits arranged in a specific pattern. Instead of forming one continuous slit through all layers, multiple shorter slits are created at different positions and depths, segmenting the cutting action to reduce the risk of sheet separation while still achieving fiber length control for improved shaping-ability.
Solution Approach 2:
The patent applies different slit characteristics to different regions and layers. Each fiber-reinforced sheet receives slits tailored to its specific fiber direction and position in the laminate, with slit depth, length, and positioning optimized for that local area rather than applying a uniform continuous slit pattern throughout.
2Stability of the object's composition
If slits are formed intermittently in a fiber-reinforced sheet laminate, then sheet separation is suppressed, but fibers cannot be cut at equal intervals leading to strength reduction
Solution Approach 1:
The patent performs preliminary planning of slit positions and dimensions before formation, calculating the optimal pattern to achieve equal fiber interval cutting across multiple sheets with different fiber directions. This preliminary design ensures that when slits are formed, they precisely intersect fibers at predetermined equal intervals, maintaining strength while using intermittent rather than continuous slits.
Solution Approach 2:
The patent employs asymmetric slit arrangements where slit positions, depths, and orientations vary between different sheets and locations to accommodate different fiber directions. This asymmetric pattern ensures that despite the intermittent nature of slits, each sheet's fibers are cut at equal intervals appropriate to that sheet's orientation, preventing strength reduction.
3Strength
If slits are formed to cut fibers at equal intervals, then strength is maintained, but shaping-ability improvement is reduced when fiber directions differ between sheets
Solution Approach 1:
The patent adds dimensional complexity by creating slits at multiple depths and orientations rather than single-plane cuts. By varying slit depth and angle across different sheets with different fiber directions, the patent achieves equal fiber interval cutting (maintaining strength) while creating a three-dimensional slit pattern that provides superior shaping-ability compared to simple two-dimensional intermittent slits.
Data Source
AI summary
A multi-stack material includes a plurality of fiber-reinforced sheets that are laminated. The fiber-reinforced sheets include a first fiber-reinforced sheet in which a first fiber extends in a first direction and a second fiber-reinforced sheet in which a second fiber extends in a second direction that is different from the first direction. The first fiber-reinforced sheet has formed therein a plurality of first slits where the first fiber is cut such that each cut-up segment of the first fiber will have an equal length. The second fiber-reinforced sheet has formed therein a plurality of second slits where the second fiber is cut such that each cut-up segment of the second fiber will have an equal length. The first slits and the second slits are arranged so as to overlap with each other when viewed from the direction of lamination.