Variable Fiber Density Cylindrical Composite for Vehicle Impact
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Solution Overview
Problem
Existing methods for manufacturing fiber-reinforced resin composites for vehicle body structures, such as center pillars, fail to appropriately differentiate strength characteristics between tensile and compressive surfaces, leading to inadequate strength or excessive material usage.
Innovation Solution
A cylindrical fiber-reinforced resin composite is created by varying the orientation and density of fibers (0° and 45° fibers) around a core, with a higher density of 0° fibers on tensile surfaces and 45° fibers wound over the entire circumference, ensuring enhanced strength for tensile stress while minimizing fiber density on compressive surfaces for weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the number of first fibers per unit area is increased on tensile surfaces to enhance tensile strength, then the strength characteristic is improved, but the material usage and weight increase
Solution Approach 1:
The patent applies local quality by varying the fiber density distribution across different surfaces of the composite. Specifically, the number of first fibers per unit area is made larger on tensile surfaces that mainly receive tensile stress upon vehicle collision, while the fiber density on compressive surfaces is reduced. This localized optimization ensures that material is concentrated where it is most needed for strength while reducing unnecessary material elsewhere.
2Ease of manufacture
If uniform fiber density is used throughout the composite to simplify manufacturing, then the ease of manufacture is improved, but the strength characteristics cannot be optimized for different stress conditions
Solution Approach 1:
The patent implements local quality by creating non-uniform fiber density distributions tailored to specific stress conditions. The first fibers are disposed with varying density - higher on tensile surfaces and lower on compressive surfaces - allowing each region of the composite to be optimized for its specific mechanical loading conditions rather than using a uniform approach throughout.
Solution Approach 2:
The patent applies asymmetry by creating intentional asymmetry in the fiber reinforcement pattern. The composite structure has different fiber densities on opposite surfaces, with the first fiber density being asymmetrically distributed to match the asymmetric stress distribution experienced during vehicle collision - higher density on tensile surfaces and lower density on compressive surfaces.
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 allows for optimized strength characteristics on both tensile and compressive surfaces, enhancing the composite's ability to absorb collision loads while reducing material usage and weight.
Implementation Method 1
curing a matrix resin with which at least the fiber-reinforced resin sheet is impregnated
Data Source
AI summary
A fiber-reinforced resin composite configured to be to be used for a vehicle body structure has a cylindrical shape and a longitudinal direction. The fiber-reinforced resin composite includes first fibers and second fibers. The first fibers are disposed along an axial direction of the cylindrical shape. The second fibers are wound over an entire circumferential surface along a direction intersecting the axial direction of the cylindrical shape. The number of the first fibers per unit area in a tensile surface that is to mainly receive tensile stress upon a collision of a vehicle body is larger than the number of the first fibers per unit area in a compressive surface that is to mainly receive compressive stress upon the collision of the vehicle body.