Multi-Layer Geometric Infill Composite for Lightweight Rigidity
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Solution Overview
Problem
Existing structural compositions face challenges in achieving a balance between rigidity, lightweight construction, and durability while minimizing material usage, and they often suffer from issues like binding, delamination, and environmental degradation of materials such as metals and fibers.
Innovation Solution
A method involving a multi-material, multi-layer geometric infilled component is developed, comprising a geometric infill pattern, a rigid composite reinforcement, and a polymeric shell, where the geometric infill is compressed with lineal reinforcements on both sides and encased in a polymeric film, using a cross-head die to form a structurally enhanced component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple materials and layers are combined to increase rigidity and strength, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The structure is divided into distinct functional layers: a geometric infill pattern layer for lightweight strength, lineal reinforcement layers for directional rigidity, and polymeric shell layers for protection and enclosure. Each layer is independently manufactured and then assembled through compression and bonding, allowing complex multi-material construction to be achieved through modular segmentation rather than monolithic manufacturing.
Solution Approach 2:
The lineal reinforcement elements are positioned within and engaged to the geometric infill structure, creating a nested arrangement where smaller reinforcement elements are integrated into the larger infill pattern. This nesting allows multiple reinforcement functions to be combined within a single structural component, increasing strength without proportionally increasing external dimensions or manufacturing complexity.
2Weight of stationary object
If geometric infill patterns are used to reduce material usage, then weight is reduced, but structural rigidity may decrease
Solution Approach 1:
The geometric infill pattern is strategically designed to provide localized reinforcement at critical stress points while maintaining lightweight construction elsewhere. The pattern density and geometry are optimized to deliver maximum rigidity where needed, allowing the structure to achieve adequate strength-to-weight ratio without requiring uniform material distribution throughout the entire component.
Solution Approach 2:
The geometric infill is combined with lineal reinforcement elements and polymeric shell materials to create a composite structure that leverages the advantages of each material: the infill provides lightweight geometric strength, the lineal reinforcements provide directional rigidity, and the polymeric shell provides protection and enclosure. This composite approach maintains rigidity while reducing overall weight compared to solid conventional materials.
3Stability of the object's composition
If metals and fibers are extruded with polymers to improve rigidity, then structural rigidity is improved, but binding and delamination issues occur
Solution Approach 1:
A polymeric bonding layer or adhesive interface is introduced between the geometric infill and lineal reinforcement elements to serve as an intermediary bonding medium. This intermediary layer ensures reliable adhesion between different materials by providing compatible surface properties and chemical bonding characteristics, preventing delamination while maintaining the structural rigidity provided by the composite construction.
4Strength
If fibers are used for reinforcement, then strength is improved, but environmental degradation occurs
Solution Approach 1:
The fiber reinforcement materials are selected and treated with modified parameters to enhance environmental resistance. This includes using chemically resistant fiber types, applying protective coatings to fibers, or selecting polymer matrices with optimized chemical composition that protects embedded fibers from moisture, UV radiation, and other environmental factors that would otherwise cause degradation over time.
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 lightweight, durable, and strong structural composition that resists lateral forces and environmental degradation, suitable for various applications including building materials and outdoor structures, while reducing material usage.
Implementation Method 1
applying an adhesive to a geometric infill; compressing the geometric infill with a lineal reinforcement on a first side and a second side of the geometric infill, wherein compressing adheres the lineal reinforcement to the first side and the second side of the geometric infill
Implementation Method 2
applying a polymer, via the cross-head die, to chemically and mechanically engage the lineal reinforcement to the geometric infill
Implementation Method 3
extruding or pultruding the component from the cross-head die
Data Source
AI summary
The present invention discloses a multi-material, multi-layer, geometric infilled component, including: providing a geometric infill to a cross-head die, the geometric infill including a first side and a second side; providing a lineal reinforcement to the cross-head die, the cross-head die configured to chemically and mechanically engage the lineal reinforcement to the geometric infill, via application of a polymer, whereby an output of the cross-head die is a component including the lineal reinforcement engaged to the first side of the geometric infill; and extruding or pultruding the component from the cross-head die.