Polymer-Graphene Foam Composite for Vehicle Weight Reduction
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Solution Overview
Problem
Existing methods for lightweighting vehicle components often compromise mechanical properties, such as flexural strength and energy absorption, when replacing traditional materials with lighter alternatives.
Innovation Solution
A composite structure comprising a foam core made from a polymer with 0.5-2.5 wt.% graphene and an overmolded skin from a polymer with 0.25-5.0 wt.% graphene, which is manufactured using injection molding, providing a reduced weight while maintaining or enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional materials are replaced with lighter materials for vehicle components, then weight is reduced and fuel economy is improved, but mechanical properties such as flexural strength and energy absorption are compromised
Solution Approach 1:
The patent applies composite materials by combining polymer matrices with graphene nanofillers to create polymer-graphene composite structures. The graphene reinforcement (0.5-5.0 wt%) provides enhanced mechanical properties including flexural strength and energy absorption, while the polymer matrix provides lightweight characteristics. This composite approach resolves the contradiction by achieving both weight reduction and improved mechanical properties simultaneously.
Solution Approach 2:
The patent utilizes porous foam core structures with controlled pore sizes (25-75 μm) and cell densities (4×10⁶ to 6×10⁶ cells/mm²). The porous architecture reduces material density and component weight while the controlled pore structure maintains structural integrity and energy absorption capabilities. When combined with graphene reinforcement, the porous structure achieves both lightweighting and enhanced mechanical performance.
2Weight of moving object
If foam core structures are used to reduce weight, then weight is reduced, but mechanical strength and structural integrity are reduced
Solution Approach 1:
The foam core is reinforced with graphene (0.5-2.5 wt%) to create a polymer-graphene composite foam structure. The graphene nanofillers strengthen the polymer matrix and enhance the mechanical properties of the foam core, allowing weight reduction through foam architecture while maintaining or improving structural integrity through graphene reinforcement.
Solution Approach 2:
The patent optimizes specific parameters including pore size (25-75 μm), cell density (4×10⁶ to 6×10⁶ cells/mm²), and graphene concentration (0.5-2.5 wt%) to achieve the desired balance between weight reduction and structural integrity. These parameter changes enable the foam core to maintain sufficient strength while achieving significant weight reduction.
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 composite structure achieves a significant weight reduction while improving flexural strength, elastic modulus, and energy absorption compared to structures without graphene, demonstrating enhanced mechanical performance.
Implementation Method 1
The composite structure includes a polymer-graphene foam core and at least one polymer-graphene solid skin
Implementation Method 2
a composite structure made from a polymer with additions of graphene (referred to herein simply as 'polymer-graphene' or 'polymer-graphene' material)
Data Source
AI summary
A composite structure includes a foam core formed from a first polymer and between about 0.5 wt. % and about 2.5 wt. % graphene. The foam core has an average pore size between about 25 μm and about 75 μm, and a cell density between about 4×106 cells/mm2 and about 6×106 cells/mm2. Also, an overmolded skin formed from a second polymer and between about 0.25 wt. % and about 5.0 wt. % graphene is disposed on the foam core. A method of manufacturing a composite structure includes injection molding a foam core from a first polymer containing between about 0.25 wt. % and about 5.0 wt. % graphene, and injection molding an overmolded skin from a second polymer containing graphene between about 0.25 wt. % and about 5.0 wt. % graphene.