Shear-Deformable Fiber Substrate via Localized Intersection Joining
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Solution Overview
Problem
Existing methods for producing sheet-shaped reinforcing fiber substrates face challenges in achieving shear deformability to conform to three-dimensional shapes, leading to low yield of reinforcing fibers and high production costs due to waste generation and difficulties in maintaining stable physical properties of fiber reinforced plastic molded articles.
Innovation Solution
A sheet-shaped reinforcing fiber substrate with a layered structure is developed, where reinforcing fiber bundles are arranged in specific directions and lengths, with intersections joined together in part to allow for shear deformability, using the fiber placement method to minimize waste and optimize fiber placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing fiber bundles are joined together by auxiliary threads (non-crimp substrate), then resistance to shear deformation is improved, but the substrate cannot easily undergo in-plane shear deformation required for complicated three dimensional shapes
Solution Approach 1:
The substrate is divided into multiple independent reinforcing fiber bundles arranged in parallel, rather than being continuously joined by auxiliary threads. This segmentation allows individual bundles to move independently, enabling shear deformation while maintaining overall structural integrity through friction at intersection points.
Solution Approach 2:
Joining is applied locally only at intersection regions where reinforcing fiber bundles from different layers directly overlap, rather than continuously along the entire length. This localized joining through friction provides sufficient restraint for structural stability while allowing the necessary shear deformability for three-dimensional shaping.
2Adaptability or versatility
If woven fabric substrate is used, then ease of shear deformation is improved, but the substrate tends to undergo excessive shear deformation and cannot maintain stable physical properties
Solution Approach 1:
Friction-based joining is applied locally at intersection regions where reinforcing fiber bundles from different layers directly overlap. This provides sufficient restraint to prevent excessive shear deformation and maintain stable physical properties, while still allowing the necessary deformability for three-dimensional shaping.
Solution Approach 2:
The substrate combines reinforcing fiber bundles with different orientations (0 degrees and 90 degrees) in a layered composite structure. This composite arrangement provides both the necessary shear deformability and the stability of physical properties by distributing stresses across multiple orientations and layers.
3Ease of manufacture
If sheet-shaped reinforcing fiber substrate with constant width is used, then ease of manufacture is improved, but yield of reinforcing fibers is low due to trimming waste
Solution Approach 1:
The substrate transitions from a static constant-width sheet to a dynamic configuration where reinforcing fiber bundles are arranged in parallel with clearances, allowing the width to vary according to the specific product shape requirements. This eliminates the need for trimming and reduces waste.
Solution Approach 2:
The substrate width parameter is changed from a fixed constant value to a variable parameter that can be adjusted according to the product shape. By arranging reinforcing fiber bundles in parallel with controlled clearances, the substrate can be manufactured in the exact width needed for each application, eliminating trimming waste.
4Loss of substance
If fiber placement method is used, then yield of reinforcing fibers is improved, but the substrate cannot easily undergo shear deformation because layers are joined over the whole layer plane
Solution Approach 1:
Joining is applied only at local intersection regions where reinforcing fiber bundles from different layers directly overlap, rather than over the entire layer plane. This localized friction-based joining maintains the benefits of fiber placement (reduced waste) while restoring the ability to undergo shear deformation by leaving non-intersection regions unjoined.
Data Source
AI summary
The present invention aims to provide a sheet-shaped reinforcing fiber substrate having shear deformability to conform to a three dimensional shape and restraining the generation of waste pieces to realize a large improve in the yield of reinforcing fibers and a reduction in production cost, and also provide a production method therefor.The sheet-shaped reinforcing fiber substrate has a layered structure containing N layers (N being an integer of 3 or more) produced by arranging a plurality of reinforcing fiber bundles with appropriate lengths and meets the requirements (1) to (5) given below:(1) in each layer, mutually adjacent reinforcing fiber bundles are aligned parallel to each other in such a manner that the clearance between mutually adjacent reinforcing fiber bundles is not smaller than the width of the reinforcing fiber bundles,(2) the reinforcing fiber bundles in a layer and those in the layer located immediately above or below and in contact therewith are aligned in different directions,(3) the length direction of the reinforcing fiber bundles in a randomly selected odd-numbered no'th layer (no being an odd number not less than 3 and not more than N) and the length direction of the reinforcing fiber bundles in the (no-2)'th layer are parallel to each other and the reinforcing fiber bundles in each layer do not overlap each other,(4) in the case where N is 4 or more, the length direction of the reinforcing fiber bundles in a randomly selected even-numbered ne'th layer (ne being an even number not less than 4 and not more than N) and the length direction of the reinforcing fiber bundles in the (ne-2)'th layer are parallel to each other and the reinforcing fiber bundles in each layer do not overlap each other, and(5) mutually intersecting reinforcing fiber bundles are joined together in at least part of the intersection regions where a reinforcing fiber bundles in any of the odd-numbered layers directly overlaps a reinforcing fiber bundle in any of the even-numbered layers.