Transparent Composite Structure With Metal Inserts for Vehicle Visibility
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Solution Overview
Problem
The challenge is to create lightweight vehicle components that maintain structural integrity while allowing for transparency, as traditional materials like stamped steel or aluminum are heavy and do not allow for visibility.
Innovation Solution
A hybrid transparent composite structure is fabricated by combining a metallic insert with a transparent composite preform made of reinforcing fibers and resin, using heat and pressure to form a structure that allows viewing through transparent portions while maintaining structural integrity, using materials like steel, aluminum, or magnesium with fibers such as carbon, glass, or basalt, and incorporating interlocking holes or mesh for resin interlock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional stamped steel or aluminum is used for vehicle structures, then structural integrity is maintained, but vehicle weight increases
Solution Approach 1:
The patent applies composite materials by combining metallic inserts with transparent composite materials (such as carbon fiber reinforced polymers or glass fiber reinforced polymers) to create a hybrid structure. This composite approach allows the structure to achieve both reduced weight and maintained structural integrity, as the composite materials provide high strength-to-weight ratio while the metallic inserts provide additional structural support and connection points.
2Illumination intensity
If opaque metallic materials are used for vehicle components, then structural strength is ensured, but visibility through the component is lost
Solution Approach 1:
The patent uses composite materials that combine transparent polymers with reinforcing fibers (carbon fiber, glass fiber, or basalt) to create a material that is both transparent and structurally strong. The transparent polymer matrix allows light transmission for visibility, while the embedded reinforcing fibers provide the necessary mechanical strength and stiffness to replace traditional opaque metallic components.
Solution Approach 2:
The patent applies local quality by using metallic inserts strategically positioned in specific locations where structural strength is most needed, while the remaining portions of the component are made from transparent composite materials. This allows the component to have varying properties in different locations - opaque and strong where metal is present, and transparent where visibility is required.
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 method results in a lightweight, structurally sound vehicle component that offers improved visibility and reduced mass compared to 100% metallic or transparent composite structures, with balanced mass, performance, and corrosion resistance.
Implementation Method 1
encapsulating the reinforcing fibers and the substrate in the transparent resin
Implementation Method 2
applying at least one of heat and pressure to form the hybrid transparent composite structure
Implementation Method 3
applying at least one of heat and pressure to form the hybrid transparent composite structure
Data Source
AI summary
A method for fabricating a hybrid transparent composite structure includes providing a metallic insert and a transparent composite preform including reinforcing fibers and transparent resin; heating the transparent composite preform; and arranging the metallic insert and the transparent composite preform in a mold and applying at least one of heat and pressure to form the hybrid transparent composite structure. At least a portion of the transparent composite preform is not obscured by the metallic insert and allows viewing through the hybrid transparent composite structure.