Fiber-Reinforced Composite Material with Graded Particle Distribution
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Solution Overview
Problem
Fiber-reinforced composite materials face challenges in maintaining a high and consistent surface quality due to temperature-dependent material properties of the matrix and continuous fibers, leading to visible textile structures and inadequate surface finish over the material's lifetime.
Innovation Solution
A fiber-reinforced composite material is developed with a specific distribution of particles, where the first volume concentration of particles in the inner spatial area is lower than the second volume concentration in the outer spatial area, preventing particle penetration into the inner area and ensuring complete impregnation by the matrix material, thus adapting thermal and viscoelastic properties to match between the inner and outer areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If particles are selected to be larger to prevent penetration into the inner spatial area, then the matrix material can completely impregnate the continuous fibers, but the particles clog the interstices between the filaments and block the matrix material from entering the inner spatial area
Solution Approach 1:
The patent applies local quality by creating different particle concentrations in different spatial areas: the inner spatial area has a lower volume concentration of particles while the outer spatial area has a higher volume concentration. This non-uniform distribution allows the matrix material to completely impregnate the continuous fibers in the inner area while maintaining particle presence in the outer area for surface quality improvement.
2Stability of the object's composition
If homogeneous volume concentrations of particles are used throughout the composite material, then the material properties are uniform, but textile structures become visible on the surface due to differential volume expansion between matrix and fibers
Solution Approach 1:
The patent implements local quality by varying the particle volume concentration spatially - lower concentration in the inner spatial area and higher concentration in the outer spatial area. This allows different regions to have different material properties optimized for their specific functions: the inner area prioritizes complete fiber impregnation while the outer area prioritizes surface quality and textile structure visibility reduction.
3Manufacturing precision
If the volume concentration of particles is increased to improve surface quality, then textile structures are reduced, but the composite material becomes less processable
Solution Approach 1:
The patent applies local quality by concentrating particles primarily in the outer spatial area while maintaining a lower particle concentration in the inner spatial area. This spatial differentiation allows high particle concentration (for surface quality) where needed while maintaining low particle concentration (for processability) in the inner area where complete matrix impregnation is critical.
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
This approach results in a substantially consistent surface finish and improved material properties, reducing the visibility of textile structures and enhancing the composite's durability under thermal and mechanical changes, while minimizing the use of particles and maintaining processability.
Implementation Method 1
the matrix material and the particles separate during the addition and/or the pressurization in such a way that a first volume concentration of the particles based on the matrix material in an inner spatial region between the filaments of a continuous fiber is less than a second volume concentration of the particles based on the matrix material in an outer space outside the filaments becomes
Implementation Method 2
providing a plastic matrix material and a quantity of particles; adding the matrix material and the particles to the fiber material; and subsequently subjecting the fiber material, the matrix material and the particles to an external pressure; wherein the matrix material and the particles separate during the addition and/or the pressurization
Data Source
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AI summary
The invention relates to a fiber-reinforced composite material (1), comprising a fiber material, which has a plurality of continuous filaments (2, 3), each formed from filaments (4), a matrix material (6) made of plastic, which fills an inner spatial region (5) between the filaments of a respective continuous filament (2, 3) and encloses the continuous filaments (2, 3) in an outer spatial region (7), and a quantity of particles (8), wherein a first volume concentration of the particles (8), relative to the matrix material (6) in the inner spatial region, is lower than a second volume concentration of the particles (8), relative to the matrix material (6) in the outer spatial region (7), wherein the second volume concentration is homogeneous and wherein the second volume concentration is modified in the outer spatial region (7) to a volume concentration of the filaments (4) in the inner spatial region relative to the matrix material (6) such that temperature-dependent material properties of the composite material (1) in the outer spatial region (7) and in the inner spatial region (5) equalize.