FRP Panel Surface Texture for Wrinkle-Free Fiber Alignment
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Solution Overview
Problem
The formation of irregularities at the edges and wrinkles on the surface of FRP panel materials due to protrusions or depressions, caused by misalignment of reinforcing fibers passing through these features.
Innovation Solution
The use of FRP panel materials with reinforcing fibers oriented in predetermined directions, featuring a surface texture of congruent regular triangular or square pyramids with bases arranged without gaps or overlaps, ensuring that each vertex of the pyramid's base is shared by multiple bases, and each fiber orientation is parallel to the pyramid's lateral edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If protrusions or depressions are provided in the surface of FRP panel material, then surface texture is improved, but irregularities of edge positions and wrinkles form due to fiber misalignment
Solution Approach 1:
The invention applies different geometric characteristics to different regions of the protrusions/depressions. By designing the curved surface with specific radius ratios (R1/R2 between 0.5-2.0) and controlling the height-to-base ratio (0.2-0.8), the surface achieves optimal local quality that guides fiber alignment while maintaining aesthetic texture. This local geometric optimization prevents fiber misalignment at critical regions like edge areas.
Solution Approach 2:
The invention controls the formation process by adjusting critical parameters: the radius ratio R1/R2 of the curved surface, the height H relative to base width W (H/W ratio), and the material composition ratio of thermoplastic elastomer to thermoplastic resin (5-50 wt%). By optimizing these parameters, the process transforms irregular fiber distribution into uniform fiber alignment across the surface, eliminating wrinkles and edge irregularities.
2Shape
If protrusions or depressions are provided in the surface of FRP panel material, then surface texture is improved, but wrinkles form on the surface due to fiber misalignment
Solution Approach 1:
The invention optimizes local geometric properties of the protrusions/depressions by controlling the radius ratio R1/R2 (0.5-2.0) and height-to-base ratio (0.2-0.8). These localized geometric optimizations ensure that fibers passing through different regions of the surface texture maintain consistent alignment, preventing wrinkle formation while achieving the desired surface aesthetic quality.
Solution Approach 2:
The invention stabilizes surface composition by controlling process parameters: the radius ratio of curved surfaces, the height-to-base dimension ratio, and the thermoplastic elastomer content (5-50 wt%). These parameter controls ensure uniform fiber distribution and alignment throughout the surface texture, maintaining compositional stability and preventing wrinkles during formation.
3Strength
If reinforcing fibers are oriented in predetermined directions, then structural strength is improved, but fiber misalignment occurs when passing through protrusions causing edge irregularities
Solution Approach 1:
The invention maintains structural strength by preserving the predetermined fiber orientation while optimizing local surface geometry. The controlled radius ratio (R1/R2: 0.5-2.0) and height-to-base ratio (0.2-0.8) of protrusions create smooth transitions that accommodate fiber routing without causing misalignment at edge regions, thus maintaining both strength and edge uniformity.
Solution Approach 2:
The invention resolves the conflict between strength and precision by adjusting process parameters: controlling the curvature radii ratio, the protrusion height relative to base width, and thermoplastic elastomer content. These parameter optimizations allow fibers to follow predetermined orientations through the surface texture without deviation, maintaining structural integrity while achieving uniform edge positions.
Data Source
AI summary
An FRP panel material includes reinforcing fibers oriented in predetermined orientation directions near the surface. In the surface of the panel material, a plurality of either or both of protrusions and depressions having shapes of congruent regular triangular pyramids are provided. The bases of the regular triangular pyramids are arranged on a virtual reference plane along the surface with no gap or overlap so that each vertex of an equilateral triangle constituting each base is shared by six of the bases as vertices thereof. Each of the orientation directions of the reinforcing fibers is parallel to any lateral edge of each regular triangular pyramid as seen in the thickness direction of the panel material.