Metal-Reinforced Composite Laminate for Lightweight Flame Resistance
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Solution Overview
Problem
Existing composite materials used in electric vehicles, such as carbon fiber-reinforced plastics, are lightweight but have limited shape stability and are prone to corrosion, while metal materials are heavy and corrosive, posing risks to battery packs due to heat generation and explosion hazards.
Innovation Solution
A composite laminate comprising a unidirectional tape layer with thermoplastic resin and continuous fibers, and a metal layer, with a minimum 40% continuous fiber content, providing improved stability and flame resistance through alternating layers and adhesive bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal materials (steel, aluminum) are used, then thermal stability and strength are improved, but weight increases and corrosion resistance deteriorates
Solution Approach 1:
The patent uses a composite laminate structure combining unidirectional tape layers (thermoplastic resin + continuous fibers) with metal layers. This composite approach achieves thermal stability through the metal layers while maintaining reduced weight through the lightweight unidirectional tape layers, resolving the contradiction between thermal stability and weight.
2Weight of moving object
If composite materials (UD tape, CFRP, GFRP) are used, then weight is reduced and corrosion resistance is improved, but shape stability deteriorates due to low elongation
Solution Approach 1:
The patent creates a hybrid composite laminate combining unidirectional tape layers with metal layers. The unidirectional tape provides lightweight and corrosion-resistant properties, while the metal layers contribute to shape stability and structural rigidity, thereby resolving the contradiction between weight reduction and shape stability.
Solution Approach 2:
The patent merges unidirectional tape layers and metal layers into an integrated laminate structure. This combination allows the material to simultaneously exhibit the lightweight and corrosion-resistant characteristics of composite materials while gaining the shape stability and strength of metal, thus resolving the contradiction.
3Object-affected harmful factors
If metal layers are added to unidirectional tape layers, then thermal stability and flame resistance are improved, but device complexity increases
Solution Approach 1:
The patent segments the laminate into alternating unidirectional tape layers and metal layers. This segmentation allows each layer to perform its specific function (unidirectional tape for lightweight and corrosion resistance, metal layers for flame resistance and thermal stability) while maintaining a relatively simple overall structure through repetitive lamination, thus resolving the contradiction between flame resistance and structural complexity.
Data Source
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AI summary
A composite laminate according to embodiments of the present disclosure includes a unidirectional tape layer including a thermoplastic resin and continuous fibers, and a first metal layer formed on the unidirectional tape layer. A content of the continuous fibers is 40 wt% or more based on the total weight of the unidirectional tape layer. The flame resistance and lightness of the composite laminate may be improved.