Braided Fiber Composite Component with Concave Core for Load Absorption
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Solution Overview
Problem
Fiber composite components used in aerospace and automotive engineering face challenges in optimizing load absorption, particularly in tensile and compressive forces, due to limitations in mechanical characteristics caused by manufacturing methods like tailored fiber placement and winding, which result in reduced component thickness and accuracy issues.
Innovation Solution
A fiber composite component design featuring a core element with a concavely constructed face surrounded by a braided fiber composite element, where the braiding technique is used to create a loop-shaped structure that optimizes load absorption, with the core element absorbing compression forces and the braided element absorbing tensile forces, allowing for efficient production of multiple components simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tailored fiber placement (TFP) with embroidering base is used, then fiber composite components can be produced with defined laying patterns, but component thickness is limited and mechanical characteristics deteriorate due to lateral contractions during tension or compression loads
Solution Approach 1:
The component is divided into a core element and an enclosing braided fiber composite element. The core element contains the embroidering base with defined laying pattern, while the braided element provides the load-bearing structure that compensates for lateral contractions, thus resolving the contradiction between manufacturability and mechanical strength.
Solution Approach 2:
The core element with embroidering base is nested within the braided fiber composite element. This nested structure allows the core to provide precise fiber placement while the outer braided layer provides the mechanical strength needed to counteract lateral contractions during loading.
2Adaptability or versatility
If winding process is used for producing compression-tension struts, then components can be produced with eyes, loops, lugs or passage openings, but only a single component can be produced and production cost increases
Solution Approach 1:
Multiple core elements are combined into a single braiding operation. The braided fiber composite element is formed simultaneously around multiple core elements, allowing multiple components with complex geometries to be produced in one process step, thus resolving the contradiction between adaptability and productivity.
Solution Approach 2:
The braiding process is made universal by enabling it to accommodate multiple core elements with different geometries (eyes, loops, lugs, passage openings) in a single operation, making the process suitable for producing various component types simultaneously and improving production efficiency.
3Adaptability or versatility
If winding at non-zero angles is used, then passage openings can be formed, but inaccurate deposit of winding layers occurs causing overlaps or gaps which negatively influence mechanical characteristics
Solution Approach 1:
The core elements with passage openings are pre-formed before the braiding process. This preliminary action allows the braiding machine to deposit layers accurately along the core elements without requiring complex angle calculations, thus resolving the contradiction between adaptability and manufacturing precision.
4Weight of moving object
If fiber composite components replace metallic components, then weight is reduced, but load absorption optimization becomes problematic
Solution Approach 1:
Different regions of the component are assigned different functions: the core element with embroidering base provides localized structural support and shape definition, while the enclosing braided element provides the primary load-bearing capacity. This local differentiation allows weight reduction while maintaining optimized load absorption characteristics.
Solution Approach 2:
The component uses a composite structure combining the core element (with embroidering base) and the braided fiber composite element. This composite material approach enables weight reduction compared to metallic components while achieving optimized load absorption through the synergistic combination of different fiber reinforcement strategies.
Data Source
AI summary
A fiber composite component is at least partially produced by braiding. It comprises a core element which has at least one concavely constructed face that is adjoined by a passage opening. Respective opposite transverse or longitudinal sides of the core element and the side of the passage opening not bounded by the core element are enclosed by a braided fiber composite loop element.