Low Density Coring Material for Lightweight Composite Structures
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Solution Overview
Problem
Existing composite materials, such as fiberglass reinforced plastic (FRP), are heavy and require significant resin usage, making them costly and difficult to use in all laminate structures, especially in small radius areas, and do not provide sufficient weight reduction.
Innovation Solution
A lightweight polymer-based coring material with a composition of 40-80 wt% resin, 0-50 wt% monomer, 0-5 wt% dispersion aid, 0-5 wt% accelerator, 3-7 wt% microspheres, and 1-5 wt% catalyst, which can be used to replace higher density materials, reducing the overall density of composites by 10-50% while maintaining or improving physical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional FRP materials are used, then structural strength is achieved, but weight and resin consumption increase significantly
Solution Approach 1:
The patent utilizes foam core materials with controlled porosity to reduce weight while maintaining structural strength. The foam structure provides sufficient mechanical properties through its cellular architecture, achieving weight reduction without sacrificing load-bearing capacity
Solution Approach 2:
The patent employs composite construction combining foam core with FRP skins to create a sandwich structure. This composite approach leverages the high strength-to-weight ratio of the foam material while using thin FRP layers for surface strength and environmental resistance, reducing overall weight compared to solid FRP
2Weight of moving object
If alternative lightweight materials like balsa or COREMAT are used, then weight reduction is achieved, but resin demand and cost increase significantly
Solution Approach 1:
The patent modifies the resin formulation parameters by incorporating foam materials that require significantly less resin for saturation compared to traditional solid core materials. The foam structure's high surface area to volume ratio allows efficient resin distribution with lower overall consumption
3Ease of manufacture
If hand laying alternative materials is attempted, then material application is possible, but difficulty increases in small radius areas
Solution Approach 1:
The patent utilizes spray application methodology, which is particularly effective for foam materials. The spray process allows the material to be atomized and applied evenly in complex geometries and small radius areas that would be difficult to reach with hand laying techniques
4Strength
If higher density materials are used, then structural properties are maintained, but weight reduction opportunity is lost
Solution Approach 1:
The patent employs foam core materials with optimized cell structures that provide sufficient mechanical properties for the application. The porous foam structure delivers adequate strength and stiffness while achieving significant weight reduction compared to solid high-density materials
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 lightweight coring material allows for reduced cycle time and construction in open molding laminate structures, providing high flexural strength and improved productivity, with the ability to be sprayed or applied by hand, and can achieve densities as low as 2.8-3.5 lbs/gal, comparable to or exceeding standard polyester FRP.
Implementation Method 1
a polymer based coring material... about 40 to about 80 wt % resin; 0 to about 50 wt % monomer; about 1 to about 5 wt % catalyst
Implementation Method 2
about 3 to about 7 wt % microspheres; wherein a density of the cured coring material is less than about 5.0 lbs/gal
Data Source
AI summary
A low density coring material is described. In one embodiment, the low density coring material consists essentially of: about 40 to about 80 wt % resin; 0 to about 50 wt % monomer; 0 to about 5 wt % dispersion aid; 0 to about 5 wt % accelerator; about 3 to about 7 wt % microspheres; and about 1 to about 5 wt % catalyst; wherein a density of the cured coring material is less than about 5.0 lbs/gal. Composites made using the low density coring material and methods of making composites are also described.