Hollow Composite Structure Component With Continuous Fiber Reinforcement
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Solution Overview
Problem
Existing methods, such as fluid injection technology (FIT), cannot produce structure components with continuous fiber reinforcement, which limits the stiffness and strength of materials, and conventional hybrid molding methods fail to create hollow profiles in a single step with continuous fibers, making the outer layer a weak point under mechanical loads.
Innovation Solution
The Endless Fiber Composite and Fluid Injection Technology (E-FIT) method integrates continuous fibers into polymer or plastic components, creating a hollow profile with high rigidity and strength by using a fluid injection technique, allowing for the production of structure components with continuous fiber reinforcement in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fluid injection technology (FIT) is used to create hollow profiles, then component rigidity is improved and weight is reduced, but continuous fiber reinforcement cannot be achieved, limiting material strength
Solution Approach 1:
The patent combines fluid injection technology (FIT) with continuous fiber reinforcement in a single manufacturing process. The hollow profile is created by injecting fluid into the mold cavity, while continuous fibers are simultaneously integrated into the polymer material, allowing both the hollow geometry and continuous fiber reinforcement to be achieved in one step rather than requiring separate manufacturing operations.
Solution Approach 2:
The patent uses composite materials consisting of polymer matrix reinforced with continuous fibers. This composite material approach allows the material to achieve high strength and stiffness properties while maintaining the lightweight characteristics needed for automotive applications. The continuous fibers provide structural reinforcement throughout the component.
2Ease of manufacture
If conventional hybrid molding methods are used with continuous fibers, then material strength is improved, but hollow profiles cannot be produced in a single step
Solution Approach 1:
The patent merges the hollow profile formation process with continuous fiber reinforcement in a single injection molding operation. The fluid injection creates the hollow cavity while the polymer material with continuous fibers fills the remaining space, achieving both geometric complexity and material reinforcement simultaneously without requiring multiple manufacturing steps.
3Strength
If hollow profiles are created using FIT, then component rigidity increases, but the outer layer becomes a weak point under mechanical loads
Solution Approach 1:
The patent applies composite materials with continuous fiber reinforcement to strengthen the outer layer of hollow profile components. The continuous fibers are distributed throughout the polymer matrix, providing enhanced tensile and compressive strength to the outer surfaces that are most susceptible to mechanical loads, while maintaining the lightweight hollow geometry for rigidity.
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
E-FIT components exhibit enhanced mechanical performance, achieving high specific rigidity and strength while maintaining low weight and cost, suitable for various applications including automobiles and aviation.
Implementation Method 1
The Endless Fiber Composite and Fluid Injection Technology (E-FIT) method integrates continuous fibers into polymer or plastic components, creating a hollow profile with high rigidity and strength by using a fluid injection technique
Data Source
AI summary
A structure component which is produced by means of a fluid injection technique and has at least one first portion in which a hollow profile is provided and at least one second portion which is reinforced with continuous fibers.