Planar Composite Material With Stitched Bidirectional Fiber Reinforcement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite materials face issues with nondirectional reinforcement, reduced reinforcing effect due to fiber bundle displacement, incomplete impregnation, and irregular thermoplastic distribution, especially in components requiring bidirectional reinforcement.
Innovation Solution
A planar composite material comprising at least one layer of thermoplastic fibers or foil and two unidirectionally oriented fiber layers, stitched and needled together to maintain fiber orientation and ensure complete impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber bundles are needled together, then the layers are connected, but the fiber bundles are opened and fibers are partially broken, causing displacement and reduced reinforcing effect
Solution Approach 1:
The patent divides the fiber reinforcement system into multiple unidirectional layers (B and B') with different orientations, where each layer maintains its fiber bundle integrity through stitching rather than needling. This segmentation allows each layer to contribute its full reinforcing effect without fiber displacement.
Solution Approach 2:
The patent introduces a thermoplastic nonwoven layer (A) as an intermediary between the unidirectional fiber layers. This intermediate layer facilitates connection between layers while allowing the use of stitching instead of needling for the reinforcing layers, thereby preserving fiber orientation and reducing fiber damage.
2Manufacturing precision
If fiber bundles are stitched together, then the individual bundles are connected, but the fiber bundles are not opened, resulting in incomplete thermoplastic impregnation
Solution Approach 1:
The patent segments the impregnation function from the reinforcement function by using a separate thermoplastic nonwoven layer (A) that is needled together with the reinforcing layers. This allows the thermoplastic to be distributed uniformly without requiring the opening of fiber bundles in the reinforcing layers.
Solution Approach 2:
The thermoplastic nonwoven layer (A) acts as an intermediary carrier of thermoplastic material. It is needled together with the unidirectional layers, allowing complete thermoplastic impregnation of the nonwoven layer while maintaining fiber bundle integrity in the reinforcing layers.
3Adaptability or versatility
If woven fabric is used for reinforcement, then bidirectional reinforcement is achieved, but fiber bundles are undulated at crossing points, reducing compressive strength
Solution Approach 1:
The patent segments the bidirectional reinforcement into two separate unidirectional layers (B and B') with orthogonal orientations. Each layer maintains straight, undulated-free fiber bundles that provide full compressive strength, while together they achieve bidirectional reinforcement capability.
4Adaptability or versatility
If woven fabric is used for reinforcement, then bidirectional reinforcement is achieved, but there are no thermoplastic at crossing points, resulting in irregular impregnation
Solution Approach 1:
The patent separates the impregnation function from the woven structure by using a thermoplastic nonwoven layer (A) that completely covers and impregnates the unidirectional layers. This eliminates dry spots at crossing points and ensures uniform thermoplastic distribution throughout the composite.
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 components with bidirectional reinforcement and uniform thermoplastic impregnation, enhancing strength and stability during processing and component formation.
Implementation Method 1
stitched and needled to each other
Implementation Method 2
stitched and needled to each other
Implementation Method 3
heat pressing in a mold
Implementation Method 4
the thermoplastic melt can soak the woven or oriented fiber layer only incompletely
Data Source
AI summary
A sheetlike composite material including at least one layer A of a nonwoven thermoplastic fiber web or a thermoplastic film, and at least two unidirectional oriented-fiber layers B and B′, the layers B and B′ having a bidirectional fiber orientation. The layers are not only needled but also stitched to one another.