Thermoplastic Composite Engine Capsule with Needled Glass Fiber Core
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Solution Overview
Problem
Existing composite materials for engine capsules lack high sound absorption, sufficient stone chip protection, tear resistance, water resistance, and oil resistance, while also requiring flame retardancy.
Innovation Solution
A thermoplastically deformable composite material with a glass fiber fabric core layer needled on both sides with a fiber fleece layer, thermally bonded to a cover layer containing polyethylene terephthalate fibers and polypropylene fibers, with an optional intermediate layer, providing a structure that is thermally and needled together to achieve enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a porous fiber fleece core layer is used to achieve sound absorption, then sound absorption improves, but stone chip protection and structural integrity deteriorate
Solution Approach 1:
The patent uses a composite structure with a porous core layer (for sound absorption) combined with cover layers containing thermoplastic fibers and reinforcing fibers (for stone chip protection). The layers are thermally bonded together to create a unified composite material that achieves both sound absorption and mechanical protection simultaneously.
Solution Approach 2:
Different regions of the composite material have different properties: the core layer is highly porous for sound absorption, while the cover layers have higher density and strength for protection. This local differentiation allows each layer to optimize its specific function while working together as a whole.
2Strength
If glass fiber content is increased to improve tear resistance and structural strength, then strength improves, but water and oil resistance deteriorate
Solution Approach 1:
The patent creates a composite material combining glass fibers (for strength and tear resistance) with thermoplastic fibers (for water and oil resistance). The thermoplastic matrix encapsulates the glass fibers, providing a hydrophobic barrier that prevents water and oil penetration while maintaining the structural benefits of the glass fiber reinforcement.
3Object-affected harmful factors
If thermoplastic fibers are added to improve water and oil resistance, then water and oil resistance improves, but sound absorption deteriorates
Solution Approach 1:
The patent applies thermoplastic fibers primarily in the cover layers rather than uniformly throughout the entire composite. This localized application provides water and oil resistance at the outer surfaces where it is most needed, while the inner porous core layer maintains its sound absorption capabilities with minimal interference from thermoplastic content.
4Strength
If multiple layers are thermally bonded and needled together to improve structural integrity, then structural strength improves, but manufacturing complexity increases
Solution Approach 1:
The patent combines thermal bonding and needling processes into an integrated manufacturing approach. The layers are first thermally bonded to create initial adhesion, then needled to mechanically interlock the structures. This combination of two processes achieves superior structural integrity while being implementable in a streamlined production workflow.
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 material exhibits improved sound absorption, stone chip protection, tear resistance, water and oil resistance, and can be flame retardant, with the needling process orienting glass fibers for effective restoration during processing, resulting in a material suitable for engine capsules and underbody protection.
Implementation Method 1
heating to temperatures above the softening temperature of the thermoplastic and pressed in a hot state
Implementation Method 2
the needling causes a partial orientation of the glass fibers in the z-direction
Data Source
AI summary
The invention relates to a thermoplastically deformable composite material made of a core layer with a glass-fibre-textile ply connected on both sides to a fibre-non-woven ply which comprises polypropylene fibres and glass fibres. There is connection between the core layer and at least one outer layer which comprises polypropylene fibres and polyethylene terephthalate fibres. The invention further relates to a process for producing the material through needling of the individual layers and heating to melt the polypropylene fibres, and also to the use of the material for automobile parts.