Hybrid Foam-Fiber Laminate for Lightweight Structural Stability
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Solution Overview
Problem
Current lightweight components in aviation and transportation sectors, such as fiber-reinforced plastics with honeycomb cores, are not sufficiently lightweight for improved energy efficiency, and there is a need for components that are both lighter and mechanically stable.
Innovation Solution
A hybrid component comprising a plastic foam base body locally connected to fiber-reinforced plastic, with laminate-free surface sections to achieve reduced weight and targeted mechanical reinforcement, utilizing a laminate structure that combines plastic foam and fiber-reinforced plastic for enhanced mechanical strength and dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced plastics with honeycomb cores are used as lightweight components, then weight reduction is achieved, but mechanical stability and structural strength are insufficient
Solution Approach 1:
The patent applies composite materials by combining plastic foam (providing lightweight and thermal insulation properties) with fiber-reinforced plastic (providing mechanical strength and stability). This hybrid composition allows the component to simultaneously achieve weight reduction and maintain structural integrity, resolving the contradiction between lightweight design and mechanical stability requirements
Solution Approach 2:
The patent implements local quality by applying fiber-reinforced plastic only in specific sections where mechanical reinforcement is needed, rather than uniformly across the entire component. This localized reinforcement approach maintains weight reduction benefits while providing targeted structural support in critical areas
2Strength
If fiber-reinforced plastic is applied to entire surface of plastic foam, then mechanical strength is improved, but weight reduction benefit is reduced
Solution Approach 1:
The patent applies fiber-reinforced plastic only in specific sections where mechanical reinforcement is needed, rather than uniformly across the entire component. This localized reinforcement approach maintains weight reduction benefits while providing targeted structural support in critical areas
Solution Approach 2:
The patent implements partial action by applying fiber-reinforced plastic to only the necessary sections of the plastic foam base body. This partial application provides sufficient mechanical strength where required without the excessive weight penalty of complete surface coverage, optimizing the strength-to-weight ratio
3Temperature
If additional thermal insulation measures are added to hybrid component, then thermal insulation performance is improved, but device complexity and production cost increase
Solution Approach 1:
The patent applies multi-functionality to the plastic foam material, which simultaneously serves as the base body structure, provides thermal insulation, and reduces component weight. By integrating multiple functions into a single material, the patent eliminates the need for separate insulation layers, thereby reducing device complexity and production costs while maintaining thermal insulation performance
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 hybrid component achieves a significant weight reduction while maintaining mechanical stability and thermal insulation properties, allowing for the potential elimination of additional insulation measures and simplifying production, thereby improving energy efficiency and reducing production costs.
Implementation Method 1
Another advantage of the proposed hybrid component can be seen in the fact that the plastic foam material has a significantly lower heat transfer coefficient compared to components made of fiber-reinforced plastics in solid material or honeycomb construction, and thus has advantageous thermal insulation properties
Implementation Method 2
The individual components of the laminate, in particular the layers, are connected to one another, in particular glued, in particular by material bonding
Data Source
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AI summary
The invention relates to a hybrid component and a method for producing the same. The hybrid component according to the invention comprises a base (2) having at least one portion that is a laminate (3) produced from a plastic foam and a fiber composite material.