Bi- or multicomponent fibres for large composite parts
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Solution Overview
Problem
The production of large composite parts, such as wind turbine blades and boat hulls, faces challenges with high-volume production due to the need for expensive equipment and processes, and existing methods result in structural inefficiencies and waste, particularly with thermoset composites which are difficult to recycle.
Innovation Solution
The development of hybrid bi- or multicomponent fibers (BCF/MCF) with a stiff reinforcing core and a thermoplastic or pre-polymerized thermoset sheath, allowing for cost-effective vacuum bagging processes that eliminate air inclusions and enable the production of large composite parts without autoclaves or expensive prepregs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum bagging with thermoplastic fibres is used for large components, then equipment investment is reduced and productivity increases, but consolidation quality deteriorates due to insufficient pressure
Solution Approach 1:
The patent changes the physical state parameter of the matrix material from solid (thermoset) to melt (thermoplastic), enabling consolidation through melting and flow rather than chemical curing. This allows vacuum bagging to achieve proper consolidation without autoclave pressure, resolving the contradiction between productivity and manufacturing precision for large components
Solution Approach 2:
The invention utilizes the phase transition of thermoplastic matrix material from solid to melt during processing. The matrix is heated to melt state for impregnation and consolidation, then cooled to solidify the composite structure. This phase transition enables effective consolidation under vacuum bagging conditions without requiring autoclave pressure, maintaining manufacturing precision while improving productivity
2Manufacturing precision
If thermoset resin infiltration and curing is used for large components, then manufacturing precision is maintained, but production time increases and productivity decreases
Solution Approach 1:
The patent changes the matrix material type from thermoset to thermoplastic, fundamentally altering the consolidation mechanism from chemical curing to physical melting and solidification. This parameter change enables faster processing cycles without sacrificing consolidation quality, directly resolving the productivity versus manufacturing precision contradiction
Solution Approach 2:
The invention replaces the chemical curing process of thermoset resins with a thermal-mechanical process using thermoplastic melting and solidification. This substitution eliminates long curing times and post-curing steps while maintaining consolidation quality through controlled cooling, thereby significantly improving production speed
3Manufacturing precision
If autoclave processing is used for large components, then manufacturing precision is improved, but device complexity and investment increase
Solution Approach 1:
The patent extracts the high-pressure consolidation function from the autoclave system by using thermoplastic matrix material that can be effectively consolidated under vacuum alone. The melting and flow characteristics of thermoplastic enable proper impregnation and consolidation without autoclave pressure, eliminating complex equipment while maintaining manufacturing precision
Solution Approach 2:
The thermoplastic matrix material acts as an intermediary that enables consolidation under vacuum conditions. Its melting and flow properties facilitate complete fibre impregnation and void elimination without requiring autoclave pressure, serving as a mediator between vacuum bagging and effective consolidation, thus reducing device complexity while maintaining precision
4Adaptability or versatility
If multiple parts are fabricated and joined for large structures, then adaptability is improved for manufacturing, but structural efficiency deteriorates due to additional weight and weak regions
Solution Approach 1:
The patent applies segmentation by dividing large structures into modular sections that can be manufactured separately using vacuum bagging with thermoplastic fibres, then joined through welding or mechanical connections. This enables manufacturing of oversized structures beyond single-autoclave capacity while maintaining structural integrity through proper joining techniques, resolving the contradiction between adaptability and structural efficiency
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 solution enables the production of high-quality, large-scale thermoplastic composite parts with reduced production costs and environmental impact, improving structural efficiency and enabling the recycling of materials, thus addressing the limitations of current methods.
Implementation Method 1
subjected to evacuation and preferably subsequent heating up to a temperature at or above the melting temperature of the second, thermoplastic material
Implementation Method 2
subjected to evacuation and preferably subsequent heating
Data Source
AI summary
Bi— or multicomponent fibre (3) comprising a reinforcing core (1) of a first material and at least one sheath (2) of a second, thermoplastic or pre-polymerized thermoset material, for the manufacturing of composite parts, the matrix of which composite parts consists of the material of said sheath (2), wherein said first material has a degradation temperature, ignition temperature, glass transition temperature, melting temperature or liquidus temperature which is higher than the melting temperature, flowing temperature, r softening temperature of said second, thermoplastic or pre-polymerized thermoset material, wherein said reinforcing core (1) has a core volume fraction (vf) defined as the volume fraction of the reinforcing core (1) in the bi- or multicomponent fibre (3), which is in the range of 0.3-0.8, and wherein along a longitudinal axis (Z) of the bi- or multicomponent fibre outer surface (4) of the sheath (2) has a corrugated, preferably irregular corrugated shape.