3D Fabric Pre-Tensioning Zigzag Yarn Layout
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Solution Overview
Problem
Existing 3D fabric manufacturing processes fail to maintain yarns in a pre-tensioned state, leading to misalignment and reduced mechanical properties in composite materials, and are limited in producing customized dimensions, shapes, and variable yarn placements, which are essential for high-performance applications.
Innovation Solution
A method and device for producing 3D fabrics by laying yarns in a zigzag formation and applying pressure to maintain them in a pre-tensioned state, allowing for customized dimensions and shapes, and incorporating bias yarns for improved mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional 3D fabric manufacturing processes are used, then production is simpler, but yarns cannot be maintained in a pre-tensioned state leading to misalignment and reduced mechanical properties
Solution Approach 1:
The patent applies preliminary action by maintaining yarns in a pre-tensioned state throughout the manufacturing process. The yarns are tensioned before, during, and after fabric formation, preventing misalignment and ensuring optimal mechanical properties in the final composite material.
Solution Approach 2:
The patent employs dynamics by using movable support structures and adjustable tensioning mechanisms that can dynamically adapt during the manufacturing process. The support structures can move to accommodate different fabric dimensions while maintaining consistent yarn tension.
2Adaptability or versatility
If conventional 3D fabric manufacturing processes are used, then production is faster, but customized dimensions and shapes cannot be produced
Solution Approach 1:
The patent uses dynamic support structures that can be repositioned and reconfigured during production. This allows the same manufacturing system to produce various customized dimensions and shapes without requiring complete process retooling, maintaining productivity while achieving versatility.
Solution Approach 2:
The patent enables parameter changes by allowing adjustment of support structure positions, yarn tension levels, and fabric formation parameters. These changes accommodate customized dimensions and shapes while maintaining efficient production through systematic parameter control.
3Manufacturing precision
If conventional 3D fabric manufacturing processes are used, then equipment is simpler, but variable yarn placements cannot be achieved
Solution Approach 1:
The patent applies segmentation by dividing the fabric formation process into discrete zones with independent support structures. Each zone can control yarn placement precisely, allowing variable yarn distributions across different regions of the fabric while using modular, manageable equipment components.
Solution Approach 2:
The patent incorporates feedback mechanisms that monitor yarn placement and tension in real-time, allowing precise control of variable yarn placements. The system adjusts parameters based on feedback to maintain manufacturing precision without requiring overly complex equipment.
4Stability of the object's composition
If yarns are not maintained in pre-tensioned state, then process is simpler, but misalignment occurs reducing mechanical properties
Solution Approach 1:
The patent applies preliminary action by establishing yarn tension before fabric formation begins and maintaining it throughout the process. This preliminary and continuous tensioning prevents yarn misalignment and ensures stable composition without requiring complex post-processing corrections.
Data Source
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AI summary
A method and device are disclosed for producing 3D fabrics including yarns/tows that remain in pre-tensioned condition. Further, the method and device produce 3D fabrics with features that increase the mechanical performance of produced materials which are highly suited for composite materials and impact injury mitigation applications. The method and device also provide a simple, quick and compact arrangement to produce economically both uniaxial and multiaxial types of 3D fabrics with specific dimensions and shapes in ‘middle-outwards’ manner to reduce production time by half by arranging the set of axial yarns in zigzag fashion between oppositely facing supports. The method and device aid automated production of 3D fabrics and their direct packaging to eliminate contamination of produced 3D fabrics. A 3D fabric produced in this way is also disclosed. The 3D fabric includes yarns/tows that remain in pre-tensioned condition.