Layered Composite Structure for High-Modulus Complex Molding
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Solution Overview
Problem
Carbon-fiber-reinforced resins face challenges in enhancing elastic modulus while maintaining isotropic properties, and composite materials with metal and fiber-reinforced resins struggle with moldability for complex shapes.
Innovation Solution
A layered composite is created by orienting chopped strand prepregs with carbon fibers in resin and layering a steel plate on the carbon-fiber-reinforced resin, ensuring pseudo-isotropic properties and a flexural modulus of at least 30 GPa, with a steel plate tensile breakage elongation of 20% or more, and controlled thickness ratios to prevent wrinkles and gaps during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber carbon-reinforced resin is used to enhance elastic modulus, then flexural modulus is improved, but moldability deteriorates and complicated molding becomes impossible
Solution Approach 1:
The continuous fiber is segmented into chopped strands (5-20mm length) while maintaining sufficient length to provide reinforcement. This segmentation allows the fibers to be randomly oriented in the resin, enabling isotropic properties and complex molding while still providing enhanced flexural modulus compared to short cut fibers.
Solution Approach 2:
The invention uses a composite structure combining chopped strand fiber reinforcement with thermoplastic resin. This composite approach allows optimization of both mechanical properties (flexural modulus) and processing characteristics (moldability) by selecting appropriate fiber length, orientation, and resin matrix properties.
2Ease of manufacture
If cut fiber carbon-reinforced resin is used to improve moldability, then ease of manufacture is improved, but elastic modulus cannot be largely enhanced
Solution Approach 1:
The invention optimizes the fiber length parameter within a specific range (5-20mm) to balance moldability and mechanical strength. This parameter optimization allows the material to be easily molded while achieving significantly enhanced elastic modulus compared to conventional cut fiber composites.
3Strength
If steel plate is layered on carbon-fiber-reinforced resin to enhance rigidity, then flexural modulus is improved, but wrinkles and gaps may occur during molding
Solution Approach 1:
The invention optimizes the steel plate thickness within a specific range (0.05-0.50mm) to balance rigidity enhancement with moldability. This thickness optimization prevents wrinkles and gaps during molding while maintaining sufficient flexural modulus for structural applications.
Solution Approach 2:
The invention merges the carbon-fiber-reinforced resin layer with the steel plate layer into a integrated layered composite structure. This combination allows the two materials to work together, providing both the moldability of the resin and the rigidity of the steel plate, while preventing defects through proper interface bonding.
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 layered composite achieves high flexural modulus and moldability, enabling complex shapes without increasing resin thickness, enhancing rigidity and maintaining isotropic properties.
Implementation Method 1
a steel plate that is layered on at least one surface of the carbon-fiber-reinforced resin and has a tensile breakage elongation φ of equal to or more than 20%
Data Source
AI summary
[Object]The purpose of the present invention is to provide a layered composite that is high in both flexural modulus and moldability.[Solving Means]Provided is a layered composite including a carbon-fiber-reinforced resin in which a chopped strand prepreg obtained by impregnating fiber in resin is oriented in such a manner as to exhibit pseudo-isotropic properties, and a steel plate that is layered on at least one surface of the carbon-fiber-reinforced resin and has a tensile breakage elongation ϕ of equal to or more than 20%, the flexural modulus in a flat plate state obtained in compliance with ASTM D-790 being equal to or more than 30 GPa.