Fibre Composite Profile with Bracing Means for Load Distribution
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Solution Overview
Problem
Existing methods for producing fiber composite materials result in 2-D fiber arrangements, leading to inefficient use of materials, increased waste, and limited load-bearing capabilities, especially in lightweight construction applications.
Innovation Solution
A fiber composite material component with a truss-like profile structure, featuring fiber bundles arranged on the outer edges and bracing means between them, allowing for a three-dimensional arrangement of continuous fibers, which reduces material usage and waste while enhancing load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If 2-D fiber arrangements are used in conventional injection molding, then the manufacturing process is simple, but the load-bearing capacity is limited and material usage is inefficient
Solution Approach 1:
The patent transitions from conventional 2-D planar fiber arrangements to a 3-D spatial configuration by arranging fiber bundles along the outer edges of the mold to form a profile structure. This dimensional change enables fibers to follow complex spatial paths and achieve superior load-bearing capacity in multiple directions simultaneously
Solution Approach 2:
The fiber reinforcement is segmented into discrete fiber bundles positioned at strategic locations (outer edges) rather than distributed uniformly throughout the component. This segmentation allows concentrated reinforcement where loads are highest while reducing overall material usage
2Strength
If more material is used to increase load-bearing capacity, then the component becomes more stable, but the weight increases and waste increases
Solution Approach 1:
The patent applies fiber reinforcement locally at the outer edges where bending and tensile loads are highest, rather than uniformly throughout the entire component. This localized quality optimization provides maximum stability where needed while minimizing weight and material waste in less critical areas
Solution Approach 2:
The invention creates a composite structure combining fiber bundles with thermoplastic material, where the fiber bundles provide targeted reinforcement for load-bearing while the thermoplastic matrix binds them together and provides structural continuity
3Loss of substance
If fiber bundles are arranged in a 3-D profile structure with bracing means, then material usage is reduced and waste is reduced, but the manufacturing complexity increases
Solution Approach 1:
The fiber bundles are pre-positioned in the mold along the desired profile path before injection molding begins. This preliminary arrangement ensures precise placement of fibers in the correct 3-D configuration, reducing material waste by eliminating the need for excessive fiber content to achieve proper distribution
Solution Approach 2:
Bracing means are introduced as intermediary elements between fiber bundles to maintain spatial separation and achieve the desired profile structure. These bracing elements facilitate the 3-D arrangement while being integrated into the final molded component
Data Source
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AI summary
The invention relates to a fibre composite material component (10) having fibre bundles (20) and a matrix made of thermoplastic and/or thermosetting material, wherein the fibre bundle (20) is arranged in such a way that it forms a profile (P) whereby bracing means (30) are arranged between the fibre bundles (20). The invention also relates to a method for producing a fibre composite material component (10), and the use of fibre bundles (20) and bracing means (30) to produce a fibre composite material component (10).