Layered Plastic Composite Structure for Uniform Glass Fiber Reinforcement
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Solution Overview
Problem
Existing fiber-reinforced composites, such as those used in Long Fiber Injection (LFI) for vehicle parts, face limitations in achieving uniform fiber distribution and thermal/mechanical property improvements due to limited fiber length and resin uniformity, leading to property deviations and restricted content of fibers.
Innovation Solution
A plastic composite structure comprising a face sheet layer, a reinforcement layer with first glass fibers and polyurethane foam, and an LFI layer with second glass fibers and polyurethane foam, where the glass fiber content and polyurethane foam ratio are optimized to enhance uniformity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber content is increased to improve mechanical properties, then strength and stiffness improve, but uniformity of fiber distribution deteriorates leading to property deviations
Solution Approach 1:
The composite is divided into distinct layers: a face sheet layer, a reinforcement layer with first glass fibers, and an LFI layer with second glass fibers. This segmentation allows each layer to have optimized fiber content and distribution, preventing property deviations while maintaining high mechanical properties.
Solution Approach 2:
Different regions of the composite have different fiber characteristics - the reinforcement layer contains first glass fibers with specific length and orientation, while the LFI layer contains second glass fibers with different characteristics. This local quality optimization ensures uniform fiber distribution in each layer while achieving high overall fiber content for improved mechanical properties.
2Ease of manufacture
If fiber length is limited to under 100 mm for LFI processing, then manufacturing ease is maintained, but thermal and mechanical properties cannot be sufficiently improved
Solution Approach 1:
The patent transitions from a single-layer LFI structure to a multi-layer structure combining traditional LFI layer with an additional reinforcement layer. This dimensional change in structure allows the use of longer first glass fibers in the reinforcement layer that would be difficult to process in a single LFI layer, while the second glass fibers in the LFI layer maintain the required length for processing.
3Productivity
If spray injection method is used for fiber and resin injection, then manufacturing efficiency is improved, but uniform coating of fibers is limited leading to property deviations
Solution Approach 1:
The manufacturing process is segmented into separate steps for forming the reinforcement layer and the LFI layer. This segmentation allows each layer to be manufactured with optimized fiber-resin distribution, avoiding the coating uniformity issues that would occur if all fibers were injected through a single spray process.
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 proposed composite structure achieves improved uniformity and mechanical properties, including enhanced flexural strength, modulus, and wettability, by optimizing glass fiber length, content, and polyurethane foam distribution.
Implementation Method 1
a reinforcement layer formed on an upper surface of the face sheet layer and including a first glass fiber and polyurethane foam, and a LFI layer formed on an upper surface of the reinforcement layer and including a second glass fiber and a polyurethane foam
Data Source
AI summary
A plastic composite comprises a face sheet layer, a reinforcement layer formed on an upper surface of the face sheet layer and including a first glass fiber and a polyurethane foam, and a LFI layer formed on an upper surface of the reinforcement layer and including a second glass fiber and a polyurethane foam.