Linear Fiber Strip Composite Reinforcement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for thin, high-strength, lightweight composite materials that are efficient to manufacture, as existing composite reinforcement methods often result in thicker structures with higher material costs and wastage.
Innovation Solution
The use of linear fiber strips with a rectangular cross-section, arranged in a two-dimensional base layer and interspersed in successive layers, which are then stitched to a substrate and molded to form a unitary reinforced composite component, allowing for reduced thickness and lower fiber wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional chopped glass fibers or woven fabrics are used for reinforcement, then the composite material provides structural strength, but the resulting components have greater thickness and higher weight
Solution Approach 1:
The reinforcement is divided into discrete linear fiber strips rather than using continuous woven fabrics or chopped fibers. These strips are arranged in specific patterns and orientations to provide structural strength while minimizing thickness and weight. The segmentation allows for optimized fiber placement where strength is actually needed.
Solution Approach 2:
The linear fiber strips are positioned locally according to specific structural requirements rather than using uniform woven patterns. This allows concentration of reinforcement in areas requiring strength while reducing material in areas where less reinforcement is needed, thereby reducing overall thickness and weight.
2Strength
If woven fabrics or non-crimp fabrics are used for reinforcement, then the composite material achieves desired strength properties, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The reinforcement system is segmented into individual linear strips that can be independently positioned and laid down, eliminating the need to handle complex woven or non-crimp fabric structures. This simplifies the manufacturing process while maintaining strength properties.
Solution Approach 2:
Instead of starting with pre-woven fabrics and then cutting or shaping them, the invention inverts the approach by laying down individual linear strips directly in their final positions. This eliminates unnecessary processing steps associated with fabric handling and simplifies manufacturing.
3Strength
If higher fiber content composites are used to reduce resin content, then the mechanical strength improves, but the manufacturing complexity and cost increase
Solution Approach 1:
The high fiber content composite is achieved through segmented linear strips rather than complex high- fiber preforms or woven structures. This segmentation allows for simpler handling and placement processes even at high fiber volumes.
Solution Approach 2:
The invention changes the geometric parameters of the fiber reinforcement from traditional woven patterns to linear strips with specific width and length dimensions. This parameter change enables high fiber content while simplifying the manufacturing 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
This method enables the production of composite components with thickness and structural performance comparable to prepreg and non-crimp fabrics, while reducing material costs and labor, achieving a molded panel thickness of 1.35 mm or less with an eight-layer configuration.
Implementation Method 1
heating the form to promote fusion of a plurality of thermoplastic fibers therein
Implementation Method 2
cooling the form until solidified with contours of the component
Data Source
AI summary
A form for a thin reinforced composite material includes a plurality of separate linear fiber strips, each having a rectangular cross section composed of reinforcement fibers. The linear fiber strips laid out in a two-dimensional base layer defining a shape of the form. A first successive layer formed with the plurality of separate linear fiber strips contacting the base layer, the linear fiber strips laid out in the first successive layer interspersed from the separate linear fiber strips in the two-dimensional base layer. A method of forming the form includes arranging the plurality of separate linear fiber strips on a substrate and tacking the plurality of separate linear fiber strips to the substrate with a plurality of stitches. A method of forming a unitary reinforced composite component from the form is further provided. The resulting component having high strength and light weight and being efficient to manufacture.