Continuous Fiber Lattice for Polymer Composite Reinforcement
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Solution Overview
Problem
There is a need for improved design strategies and manufacturing methods to create strong and lightweight composite reinforced polymer articles that can replace metal components, particularly in automotive applications, while effectively managing temperature through embedded vascular passages for fluid flow.
Innovation Solution
The use of a scaffold-like lattice structure formed from continuous fiber tow material, which can be braided or wound into specific shapes, is embedded within a molded polymer matrix, allowing for the integration of vascular passages for heat transfer fluids and reinforcement with short fibers, utilizing various materials like carbon, metal, or ceramic fibers and thermosetting resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber tow material is used to form scaffold-like lattice structures for reinforcement, then the strength and stiffness of the polymer matrix are improved, but the manufacturing complexity and process difficulty increase
Solution Approach 1:
The continuous fiber tow material is pre-formed into scaffold-like lattice structures with vascular passages before being embedded in the polymer matrix. This preliminary structuring allows complex geometries to be prepared in advance, reducing in-situ manufacturing complexity while maintaining structural integrity and mechanical properties
Solution Approach 2:
The scaffold-like lattice structure formed from continuous fiber tow material is nested within the polymer matrix, creating a hierarchical composite structure. The lattice structure itself contains nested vascular passages for fluid flow, enabling multiple functions (structural reinforcement and thermal management) within a single integrated component
2Temperature
If vascular passages are integrated into the continuous fiber lattice structure for heat transfer fluid flow, then temperature management capability is improved, but the structural integrity and manufacturing difficulty worsen
Solution Approach 1:
Vascular passages are nested within the continuous fiber tow lattice structure, allowing heat transfer fluid to flow through channels formed by the fiber arrangement. This nested configuration enables thermal management functionality to be integrated into the structural reinforcement element itself, eliminating separate cooling channels and reducing overall component complexity
Solution Approach 2:
The patent uses composite construction by combining continuous fiber tow material with polymer matrix, where the fiber lattice provides both structural strength and thermal pathways. The composite nature allows the structure to simultaneously bear mechanical loads and conduct heat through the fiber network and embedded vascular passages
3Weight of moving object
If molded polymer articles replace metal components for weight reduction, then the weight of the component is reduced, but the strength and durability compared to metal deteriorate
Solution Approach 1:
The patent employs composite materials consisting of continuous fiber tow (carbon, glass, or organic polymer) embedded in a polymer matrix. This composite construction provides high strength-to-weight ratio, enabling weight reduction compared to metal components while maintaining or exceeding mechanical strength and durability requirements for automotive applications
Solution Approach 2:
The continuous fiber tow is arranged in scaffold-like lattice structures at specific locations within the polymer matrix where strength and stiffness are most needed. This localized reinforcement strategy optimizes material distribution, providing enhanced mechanical properties at critical stress points while maintaining overall weight reduction benefits
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
This approach results in lightweight, strong composite polymer articles that effectively manage temperature and reduce weight, enhancing durability and fuel efficiency in automotive components by integrating cooling or heating systems within the structural reinforcement.
Implementation Method 1
a long tow-like structure of a group of interwound fibers, may be formed in suitable lengths with an enclosed central channel for enabling a cooling or heating fluid to be directed through the channel(s) of the tow material
Data Source
AI summary
Continuous fiber tow structures are used to form lattice reinforcing bodies to be embedded in a molded polymer matrix. The lattice structures are formed and shaped to reinforce a portion of a predetermined three-dimensional article. Optionally, some or all of the tow members of the structure may be formed with internal vascular passages for passage of a heat transfer fluid through the structure in the function of the molded polymer article. A liquid polymer is molded around the lattice structure, fully embedding the structure. The liquid polymer which may contain short-reinforcing fibers, is then solidified to form the composite reinforced polymer article. And connections may be made to the composite article for the flow of the fluid through vascular passages in the lattice structure within the article.