Variable Thickness Fiber Composite Component for Vehicle Structures
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Solution Overview
Problem
Fiber composite components for vehicle structures are expensive and heavy due to uniform thickness designs that do not optimize material distribution based on load requirements, leading to unnecessary material usage and increased production costs.
Innovation Solution
A fiber composite component with varying fiber mat thicknesses in different sections, where thicker mats are used in high-load areas and thinner mats in low-load areas, allowing for a locally optimized distribution of fiber material to reduce weight and costs, and featuring overlapping mats for enhanced connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uniform thickness fiber mats are used throughout the entire component, then dimensional stability and structural integrity are maintained, but material costs and component weight increase due to unnecessary material in low-load areas
Solution Approach 1:
The patent applies local quality by varying the fiber mat thickness according to the local load requirements of different component regions. High-load areas receive thicker fiber mats for enhanced strength, while low-load areas use thinner mats to reduce material consumption. This spatially differentiated approach optimizes both structural integrity and material efficiency.
Solution Approach 2:
The patent segments the fiber mat into multiple layers with different thicknesses, where each layer can be independently optimized for specific regions. This segmentation allows the component to have non-uniform thickness distribution, enabling material savings in low-load areas while maintaining sufficient strength in critical regions.
2Strength
If thicker fiber mats are used throughout the entire component to ensure sufficient strength in high-load areas, then structural integrity is maintained, but component weight and manufacturing costs increase
Solution Approach 1:
The patent implements local quality by providing thicker fiber mats specifically in high-load areas where strength is critical, while using thinner fiber mats in low-load areas. This localized reinforcement approach ensures adequate load-bearing capacity where needed without unnecessarily increasing component weight throughout the entire structure.
Solution Approach 2:
The patent applies partial action by providing fiber mat reinforcement only where and to the extent actually needed for structural integrity. Rather than uniformly thickening the entire component, the thicker mats are applied partially only to high-load regions, avoiding excessive material usage and associated weight increase in low-load areas.
3Quantity of substance
If variable thickness fiber mats are used to optimize material distribution, then material costs and weight are reduced, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent applies preliminary action by pre-forming fiber mats with specific thickness variations before they are placed in the mold. These preformed mats with varying thicknesses are prepared in advance according to the component's load distribution requirements, allowing the actual manufacturing process to simply involve placing and impregnating the pre-configured mats, thereby managing complexity efficiently.
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 reduces material usage and weight by optimizing fiber mat thickness based on load requirements, achieving a balance between strength and cost-effectiveness in fiber composite components.
Implementation Method 1
the binder is melted at the same time. After the binder has cooled and solidified, the individual fibers of the fiber mat stick together in such a way that the fiber mat retains the imprinted shape
Implementation Method 2
an essentially flexible and open-pored shape of the preformed fiber mat is retained, so that the injected matrix can penetrate the fiber mat and impregnate it as completely as possible
Data Source
Figure 1~2
AI summary
The invention provides a fibre composite component, particularly for a vehicle structure, with a fibre structure which comprises at least one fibre layer, wherein at least one of the at least one fibre layers is formed from a plurality of preformed fibre mats and a first preformed fibre mat has a greater fibre mat thickness than a second preformed fibre mat from the plurality of preformed fibre mats of the at least one fibre layer. A method for producing a corresponding fibre composite component is also provided.