Aligned Fiber Reinforced Molding for Complex Geometries
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Solution Overview
Problem
Current methods for fabricating high strength complex parts are limited by the inability to effectively align and shape fibers, leading to restricted geometries and poor interlayer adhesion in composite materials.
Innovation Solution
The method involves creating fiber-reinforced composite parts by providing shaped filament subunits with co-aligned continuous fibers, which are compression molded to form complex parts with enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If automated fiber placement or filament winding is used to form aligned fiber-containing parts, then fiber alignment is improved, but the selection of shapes is limited to tubular- and tank-shaped parts with convex surfaces
Solution Approach 1:
The continuous fiber tape is segmented into discrete fiber sections that can be independently positioned and shaped. This segmentation allows the fibers to be placed in complex three-dimensional configurations that are not limited to simple tubular or tank shapes, while maintaining fiber alignment within each section.
Solution Approach 2:
The invention transitions from two-dimensional fiber placement (flat tape winding) to three-dimensional fiber positioning by shaping individual fiber sections in multiple dimensions. This enables complex geometries including concave surfaces, overhangs, and intersecting curves that cannot be achieved with conventional winding methods.
2Adaptability or versatility
If automated tape laying or three-dimensional printing is used to form aligned fiber-containing parts, then shape complexity is improved, but interlayer adhesion becomes poor
Solution Approach 1:
The invention changes the physical state of the thermoplastic matrix by heating it above its melting point during the molding process. This parameter change allows the matrix to flow and thoroughly impregnate the fiber sections, creating strong interlayer adhesion through molecular entanglement and bonding, then cools to solidify the structure.
Solution Approach 2:
The fiber sections are pre-shaped and positioned in the desired complex geometry before the molding process. This preliminary action allows the fibers to be precisely placed in complex three-dimensional configurations, and the subsequent molding process then bonds these pre-positioned sections together with strong interlayer adhesion.
3Ease of manufacture
If compression molding is used to form randomly aligned fiber parts, then manufacturing simplicity is improved, but fiber alignment and strength are reduced
Solution Approach 1:
The fiber sections are pre-aligned and pre-shaped in the desired orientation and configuration before being placed in the mold cavity. This preliminary alignment action maintains fiber orientation throughout the compression molding process, resulting in parts with both manufacturing simplicity and high fiber alignment strength.
4Adaptability or versatility
If resin transfer molding is used to transfer liquid polymer matrix into complex mold, then complex geometries are improved, but process complexity and time increase
Solution Approach 1:
The invention uses a thermoplastic matrix that changes from solid to liquid state through heating, eliminating the need for liquid resin injection systems. The melted thermoplastic is simply compressed into the mold cavity, filling complex geometries through pressure-driven flow without requiring complex resin transfer molding equipment or lengthy curing cycles.
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 allows for the fabrication of high strength complex parts with improved tensile and flexural strength, reduced weight, and increased design flexibility, overcoming the limitations of existing technologies in fiber alignment and interlayer adhesion.
Implementation Method 1
a heating element configured to heat a portion of the secured filament section
Implementation Method 2
a shaping element configured to shape and to cool the heated portion of the filament section
Implementation Method 3
compression molding the layup to provide a fiber-reinforced composite part
Data Source
AI summary
Methods and apparatus for additive manufactures of complex parts using co-aligned continuous fibers are disclosed. Filament subunits having complex shapes are fabricated and inserted into a mold cavity. The layup is compression molded to form a complex part having high tensile strength.