Foamed Core Fiber Composite with Ductile Deformation Resistance
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Solution Overview
Problem
Fiber composite components with carbon or glass fiber structures lack ductile material properties, leading to poor structural integrity and risk of breakage under deformation, as they do not absorb deformation well and can tear when subjected to high loads.
Innovation Solution
A method involving a reinforcement profile surrounded by a core element, where the core element is foamed and then braided with continuous fibers, and impregnated with a matrix, enhancing the material properties to prevent breakage under high loads, allowing for a stable and lightweight fiber composite component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber composite components are made with carbon or glass fiber structures, then high rigidity and low weight are achieved, but ductile material properties are lost and the component is prone to breaking under deformation
Solution Approach 1:
The invention combines three distinct materials (fiber structure, foam core element, and ductile shell) into a composite component that achieves both low weight and high reliability. The fiber structure provides rigidity and weight reduction, the foam core provides ductility and deformation absorption, while the shell provides additional structural integrity, creating a multi-material composite that resolves the contradiction between weight and reliability
Solution Approach 2:
Different regions of the component are assigned different material properties optimized for their specific functions: the fiber structure in areas requiring high rigidity, the foam core in areas requiring ductility and energy absorption, and the shell in areas requiring structural integrity. This local differentiation allows the component to achieve both light weight and high reliability without compromising either property
2Strength
If fiber composite components are made with carbon or glass fiber structures, then high rigidity is achieved, but the component lacks ductility and can tear under large deformation
Solution Approach 1:
The invention creates a composite structure combining rigid fiber materials with a ductile foam core. The fiber structure maintains high rigidity for load-bearing functions, while the foam core provides ductility through its cellular structure that can compress and deform without tearing, allowing the component to withstand large deformations while maintaining structural stability
Solution Approach 2:
The invention changes the physical and mechanical parameters of the component by introducing a foam core element with specific density and cellular structure. This foam material has different mechanical properties (lower density, higher ductility) compared to solid fiber materials, enabling the component to exhibit both high rigidity (from fibers) and high ductility (from foam) simultaneously
3Reliability
If a reinforcement profile is enclosed with a core element and braided with continuous fibers, then break-through resistance is improved, but the manufacturing process complexity increases
Solution Approach 1:
The reinforcement profile is placed in a mold cavity before the foam core element is formed. The foam is then injected and cured in advance, enclosing the reinforcement profile within the core element. This preliminary positioning and pre-forming of the core element simplifies subsequent braiding operations and reduces manufacturing complexity while ensuring proper integration of all components
Solution Approach 2:
The invention merges multiple manufacturing steps into an integrated process: the reinforcement profile is positioned in the mold, the foam core is injected and cured around it, and then the fiber braiding is performed over the entire assembly. This combining of steps creates a unified manufacturing flow that reduces complexity compared to producing separate components and assembling them later
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 method results in a stable and break-through-proof fiber composite component with improved ductility and strength, capable of withstanding large deformations without tearing, while maintaining a lightweight and high-rigidity structure.
Implementation Method 1
wherein the step of enclosing the reinforcement profile comprises foaming to create the enclosing core element
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing a reinforced fiber composite component (10), comprising the following steps: providing a reinforcing profile (11), enclosing the reinforcing profile with a core element (12), producing a sheath (13) for the core element by braiding it with endless fibers, and impregnating the braided core element with a matrix. The invention further relates to a reinforced fiber composite component (10) comprising a core element (12) which is braided with a sheath (13), the core element enclosing a reinforcing profile (11) that is arranged inside the core element.