Fiber-reinforced composite material and method of manufacturing same
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Solution Overview
Problem
The existing methods for manufacturing carbon-fiber-reinforced plastic (CFRP) decorative parts are limited by the brittleness of carbon fibers, which slows down production, increases weight due to high specific gravity, and restricts color and weave patterns, making them unsuitable for high-speed weaving and diverse applications.
Innovation Solution
A fiber-reinforced composite material is developed using a fabric woven with synthetic and carbon fibers in various patterns, combined with resins like urethane and epoxy, allowing for high-speed weaving and low specific gravity, enabling the production of lightweight materials with customizable colors and weave patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fiber fabric is used for decorative parts, then mechanical properties are improved, but production rate decreases due to brittleness requiring special loom with mechanical grip
Solution Approach 1:
The patent uses composite fiber materials combining carbon fiber with synthetic fibers (polyester, nylon, or polypropylene) to create a fabric that maintains the mechanical strength of carbon fiber while reducing brittleness. This composite approach allows the fabric to be woven on conventional looms without requiring special mechanical grip devices, thereby improving production rate while preserving mechanical properties.
2Strength
If carbon fiber is used, then mechanical properties are improved, but weight increases due to specific gravity of 1.8
Solution Approach 1:
The patent applies local quality by using carbon fiber only in the warp direction where mechanical strength is most needed for structural integrity, while using lighter synthetic fibers in the weft direction. This selective material distribution maintains necessary mechanical properties while reducing overall weight compared to using carbon fiber throughout the entire fabric.
3Strength
If carbon fiber is used, then mechanical properties are improved, but color variety is limited
Solution Approach 1:
The patent combines carbon fiber with colored synthetic fibers (polyester, nylon, or polypropylene) in the fabric construction. The synthetic fibers can be produced in various colors, allowing the composite fabric to offer diverse color options while the carbon fiber component maintains the necessary mechanical strength and structural properties.
4Ease of manufacture
If special loom with mechanical grip is used for carbon fiber, then weaving is possible, but device complexity increases
Solution Approach 1:
The patent changes the material parameters by combining carbon fiber with synthetic fibers to reduce overall brittleness. This parameter change allows the fabric to be woven on conventional looms using standard weaving parameters and mechanisms, eliminating the need for complex special looms with mechanical grip devices while maintaining ease of manufacture.
Data Source
AI summary
A fiber-reinforced composite material and a method of manufacturing the fiber-reinforced composite material are disclosed. The fiber-reinforced composite material includes a fabric manufactured by weaving a weft including a synthetic fiber and a warp including a synthetic fiber, a carbon fiber, or a combination thereof, and a resin with which the fabric is impregnated and/or coated, wherein the resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.