Complex-Geometry Braided Sleeves With Adaptive Tow Relocation

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Solution Overview

Problem

Conventional braiding machines struggle with creating braided structures on preforms of complex geometry, leading to issues such as bunching, wrinkling, and uneven tension distribution, especially when the ratio of largest to smallest cross-sectional diameters exceeds a 3:1 ratio, and the braid architecture is not easily adaptable during the braiding process.

Innovation Solution

A braiding machine with a plurality of tow carrier devices that can form N×N braid architectures, including 10×10 braid architecture, and features like horn disks with 20 radial slots and specialized tow carrier devices to manage tension and reduce sawing, allowing for high compaction and adaptability to complex geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional 2×2 braid architecture is used on preforms with large diameter ratios, then the braiding process can handle simple geometries, but bunching and wrinkling occur when the largest cross-sectional portion exceeds three times the smallest portion

Engineering Contradiction:

Improveadaptability to complex geometriesVSAvoidbunching and wrinkling

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent implements dynamic adjustment of braid architecture during the braiding process, transitioning from 2×2 to higher N×N architectures as the preform diameter changes. This dynamic adaptation allows the system to maintain uniform tow compaction and tension across varying cross-sectional geometries, preventing bunching and wrinkling while handling complex preform shapes with large diameter ratios

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the braid architecture parameter (N value) in response to varying preform geometry. By increasing N from 2 to higher values when the diameter ratio exceeds 3:1, the system adjusts the compaction and tension distribution to match the local geometry requirements, eliminating structural defects

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If the braid architecture is fixed during the braiding process, then the machine operation is simple, but the tension distribution becomes uneven on preforms with varying cross-sectional diameters

Engineering Contradiction:

Improvemachine operation simplicityVSAvoidtension distribution uniformity

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The braiding machine incorporates dynamic control systems that automatically adjust the braid architecture and tow carrier device positions based on real-time feedback about preform geometry. This dynamic operation maintains uniform tension distribution without requiring manual intervention, resolving the contradiction between operational simplicity and tension stability

Inventive Principle:

Principle #15Dynamics

3Device complexity

If conventional braiding machines with limited tow carrier devices are used, then the device complexity is low, but the ability to form high compaction braided structures on complex geometries is insufficient

Engineering Contradiction:

Improvenumber of tow carrier devicesVSAvoidcompaction uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent segments the braiding process into multiple zones along the preform length, with different N×N braid architectures applied to different sections. This segmentation allows high compaction (N×N with large N) to be applied where needed while maintaining lower complexity elsewhere, achieving uniform compaction across the entire preform without requiring maximum complexity throughout

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements nested horn disks with radial slots that accommodate multiple tow carrier devices in a compact arrangement. This nesting approach allows a high number of tow carriers to be integrated into the machine structure without proportionally increasing the overall device complexity or footprint

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12553163B1Braided structures of complex geometry

Publication Date: 2026.02.17 A&P TECH

AI summary

A braided sleeve is formed having complex geometry, including multiple geometries along the braided sleeve's longitudinal axis. In particular, along a first portion of the braided sleeve's longitudinal axis, multiple tows are intertwined with each other. Along a second portion, at least one of the tows is removed from being intertwined with the other tows and is relocated to an interior or an exterior of the braided sleeve. A third portion of the braded sleeve along the longitudinal axis includes the removed tow being intertwined with the plurality of tows again. In this manner, the braided sleeve may provide coverage of preforms with varying diameters along the longitudinal axis of the preforms.