Additive Manufactured Preforms for Composite Structures
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Solution Overview
Problem
Conventional carbon composite preforms formed using circular needle looms produce orthogonal structures that require cutting, resulting in waste and limited design flexibility, and fabric-based preforms have uniformity issues leading to non-uniform carbon deposition and reduced composite strength.
Innovation Solution
A preform design using Fused Deposition Modeling with a non-uniform fiber density, volume, and areal weight profiles along the radius and axis, allowing for a single annular fibrous layer with varying characteristics to enhance strength and reduce waste, featuring a lug section with increased fiber density for improved composite properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional circular needle loom is used to create net-shaped preform, then preform can be formed with multiple fabric layers, but it produces orthogonal structures that require cutting and punching, resulting in waste scrap products and limited design flexibility
Solution Approach 1:
The patent changes the fundamental manufacturing approach from conventional circular needle loom to fused deposition modeling (FDM) 3D printing. This parameter change enables direct formation of annular preforms with complex internal structures without requiring cutting or punching operations, thereby eliminating waste scrap products while maintaining preform formation capability.
Solution Approach 2:
The patent replaces the mechanical circular needle loom system with an FDM 3D printing system. This substitution allows for direct digital fabrication of preforms with any desired geometry, eliminating the need for mechanical cutting and punching operations that generate waste material.
2Volume of moving object
If fabric-based preforms with multiple layers are used, then preform can achieve sufficient thickness, but design is limited by fabric characteristics and uniformity issues lead to non-uniform carbon deposition and reduced composite strength
Solution Approach 1:
The patent implements local quality by enabling spatially varying fiber density, orientation, and material properties throughout the preform structure. The FDM process allows different regions to have optimized characteristics - for example, higher fiber density in high-stress areas and controlled porosity in other regions - leading to uniform carbon deposition and enhanced composite strength while achieving required thickness.
Solution Approach 2:
The patent uses composite materials by combining thermoplastic polymer matrices with reinforcing fibers (such as carbon fibers or Kevlar) in a single-layer FDM process. This creates a fiber-reinforced composite preform that achieves both sufficient thickness and enhanced strength, eliminating the need for multiple fabric layers while ensuring uniform properties.
3Ease of manufacture
If uniform fiber density is used throughout preform, then manufacturing is simpler, but carbon deposition becomes non-uniform and composite strength is reduced
Solution Approach 1:
The patent applies parameter changes by implementing non-uniform fiber density distributions within the preform structure. The FDM process allows precise control of fiber placement, enabling higher fiber density in regions requiring greater strength and lower density in regions where less material is needed. This results in uniform carbon deposition throughout the preform and enhanced composite strength, while the digital design process maintains manufacturing simplicity.
4Ease of manufacture
If orthogonal structures are produced and then cut into circular/annular shapes, then preform can be manufactured with conventional equipment, but design flexibility is limited and waste is generated
Solution Approach 1:
The patent replaces conventional mechanical manufacturing equipment with FDM 3D printing technology. This substitution enables direct fabrication of annular preforms with complex internal geometries, lattices, and variable thickness profiles that cannot be achieved by cutting orthogonal structures. The digital design approach provides unlimited adaptability while the FDM process remains accessible through conventional additive manufacturing equipment.
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 method enables the creation of carbon composite brake pads with improved strength, wear resistance, and oxidation resistance by varying fiber properties in a single layer, reducing waste and eliminating the need for multiple fabric layers, thus enhancing the composite's structural integrity and uniformity.
Implementation Method 1
preforms made using fused deposition modeling
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A preform (100) manufactured by an additive manufacturing process is provided. The preform (100) may include an annular fibrous layer (102) made from a polymeric material, such as PAN. The annular fibrous layer (102) may comprise one or more of a non-uniform areal weight profile, non-uniform fiber volume profile, and a non-uniform fiber density profile. Such profiles may vary in either or both of the radial and axial directions (212, 214), as well as in localized regions of the preform (100). A method of producing the preform is also disclosed.