Fiber-Reinforced Reinforcing Member for 3D Rigidity Without Fiber Cuts
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Solution Overview
Problem
The use of incisions in continuous fibers for forming complex three-dimensional structures in fiber-reinforced resin structural members reduces their strength, posing a challenge in achieving lightweight and highly rigid components.
Innovation Solution
A reinforcing member with a plate-shaped design featuring convex and concave portions made of fiber-reinforced resin, joined to a main body member, which is manufactured by heating and pressurizing a prepreg sheet to form a lattice frame structure that enhances rigidity and suppresses deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If incisions are formed in continuous fibers to create complex three-dimensional structures, then shape complexity is improved, but strength is reduced
Solution Approach 1:
The plate-shaped member is divided into multiple functional regions: an outer circumferential portion for structural boundary, a convex portion for load-bearing enhancement, and multiple concave portions for weight reduction and stress distribution. This segmentation allows each region to perform its specific function optimally while maintaining overall structural integrity without compromising continuous fibers.
Solution Approach 2:
Different regions of the plate-shaped member are designed with distinct geometric properties tailored to local stress conditions. The convex portion provides localized strength enhancement where loads are concentrated, while concave portions reduce material usage in low-stress areas. This local quality differentiation enables complex three-dimensional shaping without uniform fiber interruption throughout the structure.
2Strength
If honeycomb cores are used to enhance rigidity, then rigidity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The reinforcing member integrates multiple functions into a single monolithic structure: the outer circumferential portion provides structural boundary, the convex portion enhances load-bearing capacity, and the concave portions reduce weight and distribute stress. This unified design eliminates the need for separate honeycomb core components, reducing assembly complexity while achieving comparable or superior rigidity through continuous fiber reinforcement.
Solution Approach 2:
The invention utilizes fiber-reinforced resin composite materials where continuous fibers are embedded in a matrix to create a homogeneous reinforcing member. This composite structure provides both strength and rigidity throughout the entire component, replacing the need for additional honeycomb core materials and achieving weight reduction without sacrificing structural performance.
3Strength
If continuous fibers are used to maintain strength, then strength is improved, but weight reduction becomes difficult
Solution Approach 1:
The plate-shaped member segments the distribution of continuous fibers across different functional regions. The convex portion concentrates fiber density for maximum strength where loads are applied, while concave portions reduce fiber content in non-critical areas. This spatial segmentation maintains overall structural strength while reducing total material usage and weight.
Solution Approach 2:
The design applies local quality by varying the geometric configuration of different regions to optimize the efficiency of continuous fiber usage. The convex portion's geometry maximizes fiber load-bearing capacity, while concave portions minimize material usage without compromising structural integrity. This localized optimization achieves weight reduction while preserving strength through strategic fiber placement rather than uniform distribution.
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 provides a lightweight and highly rigid structural member without the need for costly honeycomb cores, improving rigidity and load distribution while simplifying manufacturing processes.
Implementation Method 1
heating and pressurizing the prepreg sheet by using the mold to mold the plate-shaped member made of a fiber-reinforced resin
Implementation Method 2
heating and pressurizing the prepreg sheet by using the mold to mold the plate-shaped member made of a fiber-reinforced resin
Data Source
AI summary
A reinforcing member includes a plate-shaped member that is made of a fiber-reinforced resin in which a continuous fiber is used as a reinforcement fiber and that has a first surface and a second surface. The plate-shaped member includes an outer circumferential portion that defines an outer edge of the plate-shaped member, a convex portion that is convex on a side of the first surface in an area inside the outer circumferential portion, and a plurality of concave portions that are concave on the side of the first surface in an area inside the convex portion.