Braided Preform Production with Selective Filler Thread Blocking
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Solution Overview
Problem
Existing methods for producing braided preforms and fiber-reinforced components are inefficient in achieving load-oriented, material-efficient reinforcement, particularly in regions with fluctuating loads, and face challenges in industrializing the deposition of braided fabric layers.
Innovation Solution
A method involving the selective blocking of filler threads during the braiding process to create load-oriented reinforcing structures, where filler threads are temporarily held in place or omitted, allowing for adaptive reinforcement by varying the number and duration of blocked threads, enabling efficient material use and local reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous layers are used from one end of the core to the other end, then the braiding process is simple and reliable, but the material usage is inefficient in regions with fluctuating loads
Solution Approach 1:
The patent applies local quality by varying the filler thread configuration along the length of the core. Different sections of the core receive different numbers of filler threads based on local load requirements. Highly loaded regions receive more filler threads for reinforcement, while less loaded regions receive fewer threads, optimizing material efficiency while maintaining structural integrity where needed.
Solution Approach 2:
The patent implements dynamics by making the filler thread configuration adjustable and variable during the braiding process. The system can dynamically change the number of filler threads supplied to different sections of the core based on predetermined load patterns, transitioning from static continuous layers to adaptive localized reinforcement.
2Strength
If the number of layers is increased to reinforce highly loaded regions, then the component strength is improved, but the material usage and weight increase
Solution Approach 1:
Instead of uniformly increasing the number of layers throughout the entire core, the patent applies local quality by concentrating filler threads only in highly loaded regions. This localized reinforcement strategy provides the necessary strength where needed while avoiding excessive material usage in less critical areas, thereby reducing overall material consumption and weight.
Solution Approach 2:
The patent applies partial action by providing filler threads only in the portions of the core that require reinforcement. Rather than applying continuous full-strength layers throughout, the system uses partial reinforcement in specific sections, achieving the necessary strength with reduced material input.
3Loss of substance
If small reinforcing elements are applied locally on the core, then the material efficiency is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the reinforcement function into the continuous braiding process itself. Instead of applying separate reinforcing elements in a subsequent step, the filler threads are integrated directly into the braiding machine and supplied continuously or semi-continuously along with the braiding threads. This combines the reinforcement application with the primary manufacturing process, reducing device complexity and manufacturing steps.
Solution Approach 2:
The braiding machine is designed with multi-functionality, serving both the primary function of creating the braided structure and the secondary function of applying localized reinforcement through filler threads. This universal approach eliminates the need for separate reinforcement application equipment, simplifying the overall manufacturing system.
4Strength
If braided fabric layers are deposited and displaced, then the load-oriented configuration is improved, but the manufacturing reliability and industrialization become more difficult
Solution Approach 1:
The patent applies preliminary action by pre-defining the filler thread displacement patterns and timing before the actual braiding process. The control system is programmed with predetermined patterns that dictate when and how filler threads should be displaced or blocked, ensuring consistent and reliable load-oriented configuration without requiring complex real-time adjustments during manufacturing.
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 reliable, cost-effective, and material-efficient production of load-oriented fiber-reinforced components by enabling flexible reinforcement patterns, reducing material usage, and simplifying the braiding process, while maintaining performance and reliability.
Implementation Method 1
The friction between braided fabric and blocked filler thread end has to be suitably set such that the process forces do not obstruct the conveying of the core, but are large enough that the filler thread is transported along again after the blocking is removed.
Data Source
AI summary
A method for producing a braided preform, includes the steps of: a) creating a braided sleeve from filler threads and braiding threads in a braiding process, for which purpose the filler threads and braiding threads are taken off thread accumulators, b) feeding a core to the braided sleeve, c) continuing the braiding process, wherein the core is advanced such that it is braided along its length, wherein, during step c), the take-off of at least one filler thread is blocked such that the at least one filler thread is pulled out of at least one section of the braided sleeve surrounding the core.