Multi-Layer Fiber-Reinforced Profile for Internal Pressure Deformation

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Solution Overview

Problem

Existing profile parts produced by braid pultrusion methods are prone to bursting or tearing during internal pressure deformation due to limited thermal deformability and structural integrity, especially when subjected to high pressures and temperatures.

Innovation Solution

A multi-layer profile part is designed with varying layers of fiber-reinforced plastics, where each layer differs in at least one parameter such as reinforcing fibers, matrix material, or arrangement, allowing for tailored properties and functions to adapt to specific uses and processing methods, including internal pressure deformation. The inner layer is optimized with higher melting point and heat resistance, while outer layers provide strength and rigidity, and intermediate layers offer stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single-layer profile part is used to simplify structure, then device complexity is reduced, but the profile part bursts or tears during internal pressure deformation due to insufficient thermal deformability and structural integrity

Engineering Contradiction:

Improvestructure complexityVSAvoidstructural integrity during deformation

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The profile part is divided into multiple layers with different material properties. Each layer serves a specific function: the inner layer provides thermal deformability for internal pressure deformation, while outer layers provide structural strength and rigidity. This segmentation allows the profile to withstand deformation without bursting while maintaining overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The profile part uses composite material construction with at least two different materials having different properties. The inner layer uses a material with high thermal deformability and lower melting point, while outer layers use materials with higher strength and rigidity. This composite structure resolves the contradiction by combining materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

2Temperature

If the profile part is heated to enable internal pressure deformation, then thermal deformability is improved, but the risk of bursting increases due to material softening

Engineering Contradiction:

Improvethermal deformabilityVSAvoidresistance to bursting

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

Different layers of the profile part have different material properties tailored to their specific functions. The inner layer is designed with higher thermal deformability and lower melting point to facilitate heating and deformation, while outer layers maintain higher strength and rigidity to prevent bursting during the deformation process. This local differentiation of material properties resolves the contradiction between thermal deformability and strength.

Inventive Principle:

Principle #3Local quality

3Strength

If a multi-layer structure with different materials is used to enhance performance, then strength and thermal deformability are improved, but device complexity increases

Engineering Contradiction:

Improvestructural integrity and thermal deformabilityVSAvoidmulti-layer structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The profile part is segmented into multiple layers, each with specific material properties optimized for its function. The inner layer provides thermal deformability, while outer layers provide structural strength. This segmentation enables the profile to achieve both high strength and good thermal deformability, resolving the contradiction between performance enhancement and structural complexity.

Inventive Principle:

Principle #1Segmentation

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 multi-layer profile part achieves thermal deformability without bursting during internal pressure deformation, offering enhanced strength, rigidity, and media resistance, suitable for applications like vehicle body components, with potential for reduced weight and cost through material recycling and integrated production processes.

Implementation Method 1

the thermoplastic matrix material of the anti-friction coating exists heated at least to a glass transition temperature of the thermoplastic matrix material

Methodology Applied

Scientific EffectGlass transition temperature:

Implementation Method 2

a fluid or a hot gas, such as air, nitrogen, an inert gas or another suitable fluid is transported into the profile part and tensioned under pressure such that it expands until it abuts against a shaping tool

Methodology Applied

Scientific EffectInternal pressure deformation:

Data Source

PatentUS10300674B2Profile part with a plurality of layers

Publication Date: 2019.05.28 MERCEDES BENZ GROUP AG

AI summary

A profile part is disclosed. The profile part has a plurality of layers, each having a fiber reinforced plastic, where at least two layers differ in terms of at least one of the parameters characterizing the layers.