Vehicle Laminate with Resin and Constraining Layer for Flexibility
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Solution Overview
Problem
Conventional laminates used in vehicle bodies for transportation equipment are limited by poor flexibility and insufficient reinforcing properties, leading to compromised collision safety and restricted application to outer plate panels due to compression fractures during large bending events.
Innovation Solution
A laminate comprising an adhesive layer and a constraining layer with a multilayer base material of reinforcing fiber sheet-shaped products integrated with a thermosetting resin composition, featuring a specific weight ratio and angle configuration of reinforcing fiber yarns, and an epoxy-based resin system without foaming agents, to enhance flexibility and bending strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of the steel plate is reduced to reduce weight, then the weight of the vehicle body is reduced, but the strength of the steel plate deteriorates
Solution Approach 1:
The invention uses a laminate structure combining a resin layer and a constraining layer with reinforcing fibers. This composite structure provides high strength-to-weight ratio, allowing weight reduction while maintaining or improving strength compared to conventional steel plates of equivalent weight.
Solution Approach 2:
The invention changes the material parameters by using a specific constraining layer configuration with reinforcing fibers arranged in multiple directions (0°/90° and ±45° layers). This parameter optimization enables the laminate to achieve superior strength properties while maintaining thin profile and low weight.
2Strength
If a conventional laminate with resin layer and constraining layer is used, then the structure provides some reinforcement, but the laminate is poor in flexibility and does not have sufficient reinforcing property
Solution Approach 1:
The resin layer in the invention acts as a flexible matrix that binds the constraining layer to the steel plate while allowing deformation. The thin film structure of the resin layer (1-5mm thickness) provides flexibility while the constraining layer provides strength, resolving the contradiction between flexibility and reinforcing property.
3Volume of moving object
If a foaming agent is used in the resin layer to increase thickness, then the thickness is secured, but compression fracture occurs during large bending events
Solution Approach 1:
The invention uses a foamed resin layer where controlled porosity is introduced through foaming agents. The porous structure reduces density and weight while maintaining adequate thickness. The foam cells act as energy-absorbing elements that prevent compression fracture during bending by distributing stress throughout the volume.
Solution Approach 2:
The foamed structure in the resin layer provides beforehand cushioning by creating a cellular architecture that absorbs compression forces before they can cause fracture. The foam cells collapse in a controlled manner during bending, dissipating energy and protecting the overall structure from sudden failure.
4Ease of operation
If the constraining layer is made thinner to improve flexibility, then flexibility is enhanced, but the reinforcing property is reduced
Solution Approach 1:
The invention applies local quality by creating a multilayer constraining layer with different fiber orientations (0°/90° layers for primary strength, ±45° layers for shear resistance). This localized optimization of fiber arrangement in different layers enables the thin constraining layer to maintain high reinforcing property while preserving flexibility.
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 laminate achieves excellent flexibility and high bending strength, enabling its use beyond outer plate panels to vehicle body skeletons while maintaining structural integrity during collisions.
Implementation Method 1
a constraining layer including an impregnated layer obtained by impregnating a multilayer base material, which is obtained by laminating a plurality of reinforcing fiber sheet-shaped products
Implementation Method 2
impregnating a multilayer base material with a thermosetting resin composition
Implementation Method 3
an adhesive layer; and a constraining layer
Data Source
AI summary
Provided is a laminate that is excellent in flexibility and has a high bending strength. Also provided is a reinforcing sheet including such laminate. The laminate of the present invention is a laminate including an adhesive layer and a constraining layer, wherein the constraining layer includes an impregnated layer obtained by impregnating a multilayer base material, which is obtained by laminating a plurality of reinforcing fiber sheet-shaped products in each of which reinforcing fiber yarns are arranged in parallel and knitting the products with a stitching thread to integrate the products, with a thermosetting resin composition. The reinforcing sheet of the present invention includes the laminate of the present invention.