Single-Layer Fiber-Reinforced Door Module Adhesion
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Solution Overview
Problem
Existing door modules made from semifinished fiber matrix products face issues with adhesion between layers, particularly at lower temperatures, leading to potential delamination, which is a concern for applications in vehicles exposed to varying and extreme temperatures.
Innovation Solution
The development of single-layer semifinished fiber matrix products with continuous fibers, where the entire thickness is uniformly impregnated with thermoplastics, ensuring high fiber volume content and minimal air or gas volume, thereby enhancing adhesion and stability across the composite structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-layer composite structures are used to achieve high mechanical properties and lightweight construction, then strength and stiffness are improved, but adhesion between layers deteriorates at low temperatures leading to delamination
Solution Approach 1:
The patent divides the composite structure into multiple discrete plies (1 to 100 semifinished fiber product plies) that are stacked and impregnated together. This segmentation allows each ply to maintain its structural integrity while contributing to the overall mechanical properties, and the impregnation process ensures reliable bonding between segmented layers without delamination at low temperatures.
Solution Approach 2:
The patent uses composite materials consisting of semifinished fiber products (such as glass fiber, carbon fiber, or aramid fiber) impregnated with thermoplastic or thermosetting resin to create a single-layer structure. This composite approach achieves high mechanical properties and lightweight construction while maintaining adhesion stability, as the resin fully penetrates and bonds the fiber plies into a unified structure that resists delamination at low temperatures.
2Strength
If continuous fiber-reinforced structures are used to achieve high strength and stiffness, then mechanical properties are improved, but manufacturing complexity increases to prevent fiber displacement
Solution Approach 1:
The patent applies preliminary action by pre-arranging the semifinished fiber products in the desired ply configuration before impregnation. The fiber plies are stacked and positioned in advance, and then the resin is applied to impregnate and fix them in place. This preliminary arrangement ensures that the continuous fibers maintain their intended orientation and position throughout the manufacturing process, achieving high mechanical properties without requiring complex real-time control mechanisms to prevent fiber displacement.
3Weight of moving object
If thin-walled components are produced to reduce weight, then weight reduction is achieved, but structural stability and resistance to delamination deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the number of fiber plies (1 to 100 plies) and their basis weight (5 to 3000 g/m2 each) to achieve the desired wall thickness and weight reduction. Simultaneously, the impregnation process parameters are optimized to ensure complete resin penetration and full adhesion between plies. This allows the production of thin-walled components that maintain structural stability and resistance to delamination, as the resin fully bonds the thin wall structure without creating weak interfaces.
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
This approach results in improved mechanical properties, including higher energy absorption and stability at low temperatures, reducing the likelihood of delamination and offering advantages in weight reduction and crash resistance compared to traditional materials.
Implementation Method 1
impregnating semifinished fiber products with at least one thermoplastic
Implementation Method 2
the entirety of all semifinished fiber product plies has been impregnated with at least one thermoplastic
Data Source
AI summary
The present invention relates to door modules comprising at least one single-layer, continuous fiber-reinforced semifinished fiber matrix product which is obtained by impregnating semifinished fiber products with at least one thermoplastic, and to the use thereof in vehicles or in buildings.