Segmented Slits in CFRP Laminates for Wrinkle-Free Bending
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Solution Overview
Problem
The challenge in manufacturing laminate structures, such as carbon fiber-reinforced plastic (CFRP) components, is that fiber-reinforced sheets lack stretchability, leading to potential wrinkles and reduced strength when bent, especially when fibers align with compressive or tensile forces, and existing methods like forming slits in individual sheets do not effectively address these issues in laminated sheet configurations.
Innovation Solution
A laminate structure and manufacturing method involving multiple fiber-reinforced sheet laminates, where slits are strategically formed in the first sheet laminate at the end portion and second sheet laminate at the intermediate portion, with slits in the first laminate extending in a predetermined direction and intersecting direction, and in the second laminate extending over the entire area where forces act, to enhance shaping-ability and prevent wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If continuous and long slits are formed in the fiber-reinforced sheet laminate to improve shaping-ability, then the shaping-ability is improved, but the laminate structure may collapse due to fiber-reinforced sheets curling up or coming apart
Solution Approach 1:
The patent divides the continuous slits into multiple discrete slits arranged in a specific pattern. Instead of forming one long continuous slit that causes sheets to separate, the invention creates multiple shorter slits distributed across the laminate, which individually cut fibers to improve shaping while collectively maintaining structural integrity through their distributed arrangement
Solution Approach 2:
The patent applies different slit configurations to different regions of the laminate. The multiple slits are arranged with specific spacing and orientation patterns that adapt to local stress distributions and fiber orientations, providing optimal shaping-ability in regions requiring it while maintaining stability in regions where continuous structure is critical
2Stability of the object's composition
If slits are not formed in the fiber-reinforced sheet laminate to maintain shape stability, then the laminate structure stability is maintained, but the shaping-ability is suppressed
Solution Approach 1:
The invention segments the slit formation into multiple discrete locations rather than avoiding slits entirely or using one long continuous slit. This segmentation allows localized fiber cutting to improve shaping in specific areas while preserving the overall continuous structure of the laminate for stability
Solution Approach 2:
The patent applies partial action by forming slits only in specific regions where shaping-ability improvement is needed, rather than across the entire laminate. The multiple slits are strategically positioned to provide sufficient shaping capability without excessive cutting that would compromise overall structure
Data Source
AI summary
A charge is formed of a plurality of layers of fiber-reinforced sheets. The charge includes an outermost-layer multi-stack member disposed at each end section in a layering direction; and an intermediate-layer multi-stack member disposed in an intermediate section in the layering direction. The outermost-layer multi-stack member includes a fiber-reinforced sheet in which fibers extend in an X-axis direction in which compression force or tensile force acts when the charge is subjected to bending processing; and has formed therein a plurality of incisions that penetrate in the layering direction and extend in a Y-axis direction. The plurality of incisions are disposed side by side at prescribed intervals in the Y-axis direction and the X-axis direction. An incision that penetrates in the layering direction and extends in the Y-axis direction is formed in the intermediate-layer multi-stack member. The incision extends roughly the entire region affected by compression force or tensile force.