Automated Bias-Ply Preparation Device for Composite Laminates
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Solution Overview
Problem
Current composite laminate formation methods are limited by the availability of pre-preg materials with only 0° and 0/90 fiber orientations, making it difficult to achieve complex fiber orientations necessary for high-strength, low-weight structures, particularly for applications requiring continuous rolls with various fiber angles like 30°, 45°, 60°, 90°, 120°, 135°, and 150°.
Innovation Solution
A material preparation device that includes a bias-ply assembly, feedstock assembly, and application head, allowing for the conversion of pre-preg material from standard orientations to bias-plies with select fiber orientations by crossing paths at specific angles, enabling the formation of continuous rolls with diverse fiber orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pre-preg material is supplied only in standard 0° and 0/90° orientations, then manufacturing simplicity is maintained, but the ability to form complex shaped structures with tailored fiber orientations is limited
Solution Approach 1:
The system pre-forms bias-ply rolls with various fiber orientations (30°, 45°, 60°, 90°, 120°, 135°, 150°) before the actual laminate formation process. This preliminary preparation of material with different orientations allows the automated layup system to efficiently create complex shaped structures without requiring complex real-time material manipulation
Solution Approach 2:
The bias-ply preparation device dynamically adjusts the orientation of fibers during the roll formation process. By controlling the movement and positioning of pre-preg material through the device, it can create rolls with various fiber angles, transforming a static material supply system into a dynamic one that adapts to different structural requirements
2Productivity
If manual methods are used to create bias-ply rolls with different fiber orientations, then flexibility in orientation selection is achieved, but productivity and consistency are reduced
Solution Approach 1:
The bias-ply preparation device is designed to automatically form rolls with various fiber orientations without requiring manual intervention for each orientation change. The system self-adjusts and automates the complex process of creating bias-ply material, thereby increasing productivity while maintaining consistent and accurate fiber orientations through controlled mechanical processes
3Adaptability or versatility
If multiple separate material supplies are used for different fiber orientations, then orientation variety is achieved, but material handling complexity and time consumption increase
Solution Approach 1:
The bias-ply preparation device serves multiple functions by being able to produce rolls with various fiber orientations (30°, 45°, 60°, 90°, 120°, 135°, 150°) using a single integrated system. This multi-functional capability eliminates the need for multiple separate material supplies and reduces the time required to switch between different orientations, as the same device can produce any required orientation on demand
Data Source
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Figure 3A~3C
AI summary
A material preparation device (100) is provided. The material preparation device includes a bias-ply assembly (105), a feedstock assembly (103) and an application head (130). The bias-ply assembly is configured to pass a bias-ply backing material (146) along a first path. The feedstock assembly is configured to pass a feedstock (116) along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg (300, 660) from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second different orientation relative to an edge of the formed bias-ply.