Multilayer Composite Automotive Components with Resin-Bonded Fibers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current materials and processes for automotive components, such as polymeric materials and multilayer composites, fail to meet mechanical strength and thermal stability requirements, particularly for vehicle interior components, and are economically inefficient due to high production costs and weight sensitivity.
Innovation Solution
A multilayer composite material structure comprising a central element sandwiched between reinforcement layers, with structural layers made of needle-punched fibers or expanded thermoplastic polymers impregnated with a thermosetting resin, and reinforcement layers of glass, carbon, or aramid fibers, processed through hot-pressing thermoforming to achieve variable mechanical properties and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If multilayer composite materials are used to reduce weight, then weight is reduced, but mechanical strength is insufficient for vehicle interior components
Solution Approach 1:
The patent employs a multilayer composite structure combining different materials (structural layers, reinforcement layers with glass/carbon/aramid fibers, and functional layers) to achieve both weight reduction and high mechanical strength. The composite nature allows optimization of each layer's properties to contribute to overall performance, resolving the contradiction between lightweight and strong requirements for vehicle interior components.
Solution Approach 2:
The component is divided into multiple functional layers including structural layers, reinforcement layers, and functional layers. Each layer has specific properties optimized for its function, allowing the overall structure to achieve high strength-to-weight ratio while meeting mechanical strength requirements for safety-critical interior components.
2Strength
If polymeric materials are used to achieve high mechanical strength, then mechanical strength is improved, but thermal stability is insufficient
Solution Approach 1:
The patent combines thermoplastic structural layers with thermosetting resin-impregnated reinforcement layers containing high-temperature stable fibers (glass, carbon, or aramid). This composite structure provides both the mechanical strength of polymeric materials and the thermal stability of the fiber reinforcement, resolving the contradiction between strength and thermal resistance for components exposed to sunlight and interior heat.
3Strength
If injection moulding is used to produce components, then mechanical strength is achieved, but production cost is high
Solution Approach 1:
The manufacturing process is segmented into separate steps: producing structural layers, producing reinforcement layers with resin impregnation, and assembling them. This modular approach allows for more cost-effective production compared to expensive injection molding tools, while still achieving high mechanical strength through the composite structure and thermosetting resin bonding.
4Ease of manufacture
If multilayer composite materials are used to reduce production cost, then production cost is reduced, but mechanical strength is insufficient
Solution Approach 1:
The patent uses a composite structure with thermoplastic structural layers providing cost-effective manufacturing and thermosetting resin-impregnated reinforcement layers providing high mechanical strength. The combination achieves both cost reduction and strength enhancement, resolving the contradiction between production cost and mechanical strength for vehicle interior components.
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 solution provides automotive components with enhanced mechanical strength, thermal stability, and reduced weight, while allowing for modulated mechanical properties and cost-effective production, surpassing conventional materials in performance and efficiency.
Implementation Method 1
said structural layers (A) being impregnated with a thermosetting resin
Implementation Method 2
processed through hot-pressing thermoforming
Implementation Method 3
having insufficient stability against thermal stresses (for example, direct and prolonged exposure to sunlight)
Data Source
AI summary
An article may be made of multilayer composite material. The multilayer composite material may include central element (I) between first and second reinforcement layers (B) to form structure (B)-(I)-(B). The central element (I) may include: first and second structural layers (A), each of the first and second structural layers (A) including at least one mat of needle punched thermoplastic fibers selected from polyester fibers, polyamide fibers, polypropylene fibers, or mixtures thereof bonded through thermosetting resin; and third reinforcement layer (B) between the first and second structural layers (A). The first, second, and third reinforcement layers (B) each may include fibrous material, including one or more types of fibers selected from glass fibers, natural fibers, carbon fibers, basalt fibers, aramid fibers, or mixtures thereof.