3D Fiber Structure Dewatering on Permeable Substrates
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Solution Overview
Problem
Existing methods for producing 3D fiber structures, particularly 3D wood fiber structures, are energy-intensive and time-consuming, and deteriorate the bulk properties of the structure during dewatering.
Innovation Solution
A method involving a liquid-permeable substrate with a dispenser and vacuum units to apply controlled dewatering pressures and ultrasonic radiation to produce a 3D fiber structure efficiently, maintaining the bulk properties and enabling continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional manufacturing methods (molding, weaving, knitting) are used to produce fiber structures, then production is limited to 2D configurations and simple geometries, but the ability to create complex 3D structures with varying fiber orientations and densities is insufficient
Solution Approach 1:
The manufacturing process is segmented into discrete deposition steps where individual fibers or tows are placed sequentially according to digital design specifications. Each fiber placement operation can be independently controlled to achieve complex 3D architectures that cannot be produced by conventional molding or weaving methods.
Solution Approach 2:
The invention transitions from 2D fiber arrangement in conventional manufacturing to 3D fiber positioning by adding the vertical dimension through controlled fiber placement at multiple layers and angles. This enables creation of truly three-dimensional structures with fibers oriented in any direction in space.
2Productivity
If manual fiber placement methods are used, then small batches can be produced with some customization, but productivity and manufacturing time are excessively long
Solution Approach 1:
Manual mechanical fiber placement is replaced with automated robotic systems that can precisely deposit fibers at high speeds according to pre-programmed paths. The automated system eliminates the time-consuming manual operations while maintaining or improving placement precision.
Solution Approach 2:
The manufacturing process parameters such as deposition speed, fiber placement rate, and layer transition time are optimized and controlled by computer systems. These parameter changes enable significantly faster production compared to manual methods while maintaining quality standards.
3Adaptability or versatility
If conventional molding processes are used, then production is faster than manual methods, but design flexibility and customization capability are severely limited
Solution Approach 1:
The manufacturing system is made dynamic and reconfigurable through computer control, allowing rapid adaptation to different product designs without requiring new physical tooling. The robotic placement system can be reprogrammed to produce various geometries, fiber orientations, and density distributions, providing both design flexibility and maintained productivity.
4Reliability
If high-volume production methods are used, then manufacturing efficiency increases, but quality control and defect detection become more difficult
Solution Approach 1:
The automated fiber placement system incorporates feedback mechanisms including sensors that monitor fiber placement accuracy, resin distribution, and structural formation in real-time. This feedback enables continuous quality control and immediate correction of deviations, ensuring consistent quality even during high-volume production.
Data Source
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AI summary
The present disclosure relates to a method (100) for producing 3D fiber structures, the method (100) comprising the steps of: feeding (101) a foamed fiber furnish (2) to an apparatus (1), the apparatus (1) comprising a liquid-permeable substrate means (3) having a first side (4) and an opposing second side (5), a dispenser (6) having an outlet (7), wherein at least one of 5 the dispenser (6) and the substrate means (3) travel with respect to the other. Further comprising the step of dispensing (102), by means of the dispenser (6), a layer (2) of foamed fiber furnish to the first side of said liquid-permeable substrate means (3), wherein the apparatus (1) further comprises at least a reservoir (8) and a first vacuum unit (9) associated with the second side (5) of the liquid-permeable substrate means (3) so to collect fluid 10 discharge from the dispensed layer (2) of foamed fiber furnish. Further comprising the step of applying (103) at least a first dewatering pressure to at least a part of the second side (5) of said substrate means (3).