Plastic Structural Component with Random Fiber Collective
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Solution Overview
Problem
Existing structural components in vehicles, particularly those made of metallic materials, face challenges in achieving a balance between high rigidity and low weight, tend to corrode, and can splinter during impacts, posing safety risks, while plastic components with glass or carbon fibers are brittle and prone to splintering, limiting their use in critical areas.
Innovation Solution
A structural component made of plastic reinforced with a fiber collective of random fibers, which are dispersed in a disordered manner, providing mechanical stability and preventing splintering in thin-walled regions, especially in edge areas where space is limited, using random fibers like glass or carbon fibers up to 50 mm in length, and a method involving injection molding or impact extrusion to integrate these fibers into the plastic matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for structural components, then high rigidity and strength are achieved, but weight increases and production costs increase
Solution Approach 1:
The patent employs fiber-reinforced plastic composite materials consisting of a thermoplastic matrix and dispersed short fibers (glass, carbon, or organic fibers). This composite structure combines the light weight of plastics with the strength of fibers, achieving specific strength and rigidity comparable to metals while significantly reducing weight and production costs.
2Weight of moving object
If plastic materials with glass or carbon fibers are used, then weight is reduced and production costs are lowered, but the material becomes brittle and prone to splintering under extreme conditions
Solution Approach 1:
The patent applies local quality enhancement by specifically reinforcing critical regions (edge areas and narrow sides) with fiber collectives. The fiber concentration and distribution are optimized locally in these high-stress zones while maintaining lighter construction in non-critical areas, thereby improving impact resistance where needed without compromising overall weight reduction.
Solution Approach 2:
The patent modifies material parameters by controlling fiber length (5-50 mm), fiber diameter (5-20 µm), and fiber concentration (10-40 wt%) in the thermoplastic matrix. These parameter optimizations enhance the material's toughness and impact resistance while maintaining processability and preventing brittle failure during collisions.
3Weight of moving object
If thin-walled elements are used in impact areas, then weight is reduced, but the elements tend to splinter and fragment under impact
Solution Approach 1:
The patent implements beforehand cushioning by incorporating fiber collectives into the thin-walled structure before impact occurs. The dispersed short fibers act as reinforcement that prevents crack propagation and splintering during impact, effectively cushioning the structural elements against fragmentation while maintaining thin-wall design for weight reduction.
4Reliability
If additional catch straps are added to metal components to prevent splinter cohesion, then safety is improved, but device complexity and production costs increase
Solution Approach 1:
The patent extracts the need for additional catch straps by inherently designing the plastic composite material to prevent splintering through its fiber reinforcement mechanism. The short fiber-dispersed composite structure naturally maintains fragment cohesion during impact without requiring separate metal fastening elements, thereby simplifying the overall structure and reducing production complexity.
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 enables the use of lightweight plastic components with enhanced strength and stiffness, preventing splintering and detachment during impacts, while reducing production costs and weight, thus improving safety and stability without increasing component size in critical regions.
Implementation Method 1
a structural component made of a plastic material and is reinforced with a fiber collective in the region or a section of a narrow side of the structural component, wherein the fiber collective comprises random fibers
Data Source
AI summary
A structural component for use in a vehicle, wherein the structural component (10) is made of a plastic material and is reinforced with a fiber collective (8) in the region of a narrow side, wherein the fiber collective (8) comprises random fibers.