Unidirectional fiber composite system for structural repairs and reinforcement
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Solution Overview
Problem
Existing repair and reinforcement systems for conduit assemblies, containment structures, and building structures are often disruptive, costly, and lack durability, necessitating a need for quick, versatile, and cost-effective solutions.
Innovation Solution
A composite system comprising unidirectional fibers adhered with a resinous material, where the fibers are non-mechanically connected and aligned parallel to maximize tensile properties, with optional insulating layers for conductive structures, and a repair kit with pre-impregnated fibers for moisture-activated curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional repair and reinforcement systems are used for conduit assemblies and structures, then structural integrity can be restored, but the repair process is disruptive, costly, and lacks durability
Solution Approach 1:
The patent applies composite materials consisting of unidirectional fibers (such as carbon, glass, or aramid) embedded in a polymer matrix to create reinforcement systems that provide high strength-to-weight ratios, durability, and resistance to environmental degradation. This composite structure enables reliable structural reinforcement while reducing the complexity and cost of repair operations compared to traditional methods.
Solution Approach 2:
The patent utilizes parameters such as fiber orientation (unidirectional alignment), fiber-to-matrix ratio, and polymer matrix composition to optimize the mechanical properties of the reinforcement system. By controlling these parameters, the system achieves maximum tensile strength and durability while minimizing material usage and repair complexity.
2Strength
If unidirectional fibers are used to maximize tensile properties, then reinforcement efficiency is improved, but the system becomes more complex regarding fiber alignment and adhesion
Solution Approach 1:
The patent segments the reinforcement system into distinct unidirectional fiber layers, each optimized for specific tensile loading directions. This segmentation allows for precise control of fiber alignment within each layer while simplifying the overall manufacturing process through modular layering, where each layer can be independently processed and bonded.
Solution Approach 2:
The patent employs a polymer matrix as an intermediary material that bonds unidirectional fibers together, transferring loads between fibers and maintaining their aligned configuration. This matrix mediator simplifies the system by eliminating the need for complex mechanical fastening or inter-fiber bonding mechanisms, as the polymer provides both adhesion and structural continuity.
3Strength
If the composite system is applied to reinforce structures, then structural integrity is improved, but the thickness of the structure increases
Solution Approach 1:
The patent employs thin-film composite structures where unidirectional fiber layers are embedded in thin polymer matrices. This thin-film approach provides high structural reinforcement with minimal thickness increase, as the high-strength fibers deliver maximum tensile properties in a compact configuration that closely adheres to the substrate surface.
Solution Approach 2:
The use of high-performance composite materials with exceptional strength-to-thickness ratios enables the system to achieve required structural integrity with minimal material thickness. The unidirectional fiber architecture maximizes tensile strength per unit thickness, allowing thin reinforcement layers to provide substantial structural improvement.
4Reliability
If conductive structures are reinforced with conductive fibers, then electrical properties are maintained, but thermal and electrical insulation requirements create additional complexity
Solution Approach 1:
The patent applies local quality by using conductive fibers (such as carbon or metal) in specific regions where electrical conductivity is required, while employing non-conductive fibers (such as glass or aramid) in regions requiring thermal or electrical insulation. This spatial variation in material properties optimizes both electrical performance and insulation requirements without adding uniform complexity throughout the entire structure.
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 system provides efficient reinforcement with minimal thickness increase, maintaining tensile strength and integrity while being adaptable to various environments and structures, including electrical and thermal insulation.
Implementation Method 1
A resinous material adheres the plurality of unidirectional fibers to each other such that each one of the plurality of unidirectional fiber is adhered to at least one adjacent one of the plurality of unidirectional fibers
Implementation Method 2
A second insulating layer is adhered to the first unidirectional fiber layer by the resinous material and/or another resinous material. The second insulating layer separates the electrically and/or heat conductive material(s) in the first unidirectional fiber layer from direct contact with an electrically and/or heat conductive physical structure
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A composite system for the reinforcement of physical structures includes a plurality of unidirectional fibers arranged with respective longitudinal axes generally parallel to each other over a substantial portion of a length of each unidirectional fiber. The plurality of unidirectional fibers are non-mechanically connected. A resinous material adheres the plurality of unidirectional fibers to each other such that each one of the plurality of unidirectional fiber is adhered to at least one adjacent one of the plurality of unidirectional fibers along a substantial portion of the length of the adjacent one of the plurality unidirectional fibers.