Carbon Fibre Trim Surface Pattern via Misaligned Layering

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Solution Overview

Problem

Existing methods for manufacturing carbon fibre composite components fail to produce trim components with unique aesthetic surface patterns, limiting their application in high-value consumer goods where a 'signature finish' is desired.

Innovation Solution

A method involving a male component with a control surface matching the trim component's B surface, where unidirectional carbon fibre sheets are layered with misaligned fibres, cured, and then machined using specific cutting tools at controlled angles to create a unique A surface pattern, followed by smoothing and lacquering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional manufacturing methods are used for carbon fibre composite components, then light weight and high strength are achieved, but unique aesthetic surface patterns cannot be produced

Engineering Contradiction:

Improvesurface pattern precisionVSAvoidaesthetic application versatility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The method performs preliminary actions by creating a male component with a control surface that corresponds to the desired B surface of the trim component before the actual trimming process. This preliminary structure guides the subsequent machining operations to achieve the unique aesthetic surface pattern on the A surface.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the cutting parameters by specifying a cutting angle in the range of 2 to 45 degrees with respect to the plane of the sheets. This parameter change enables the cutting tool to create distinctive surface patterns on the carbon fibre layers while maintaining structural integrity.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If multiple carbon fibre sheets are layered with misaligned fibres to create thickness, then the trim component achieves sufficient material depth for machining, but the manufacturing process complexity increases

Engineering Contradiction:

Improvethickness controlVSAvoidlayering process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The carbon fibre layer is segmented into multiple individual sheets that are placed consecutively. Each sheet can be rotated with respect to the preceding sheet, allowing independent control of fibre orientation while maintaining overall thickness control through the layering process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention adds dimensional control by rotating each sheet with respect to the preceding sheet, creating misaligned fibre directions in three-dimensional space. This dimensional approach allows thickness control while managing the complexity of fibre orientation across multiple layers.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If the cutting tool is arranged to cut at a specific angle to create unique surface patterns, then aesthetic quality is improved, but manufacturing process complexity increases

Engineering Contradiction:

Improvesurface finish qualityVSAvoidmachining operation simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention specifies a cutting angle parameter in the range of 2 to 45 degrees with respect to the plane of the sheets. This parameter change transforms the machining operation to create unique aesthetic surface patterns while maintaining a defined, controllable process that balances quality with manufacturability.

Inventive Principle:

Principle #35Parameter changes

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

Enables the production of carbon fibre trim components with distinctive surface patterns, enhancing their aesthetic appeal and consumer recognition, suitable for high-value applications beyond traditional uses.

Implementation Method 1

cutting the outer surface of the carbon fibre layer to expose an A surface of the trim component using a cutting tool travelling along a machining path, the cutting tool being arranged to cut the outer surface at a cutting angle in the range of 2 to 45 degrees with respect to the plane of the sheets

Methodology Applied

Scientific EffectMechanical cutting: Abrasion

Implementation Method 2

curing the carbon fibre layer on the male component

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentEP3509825B1Method of manufacturing products from carbon fibre composite materials

Publication Date: 2023.02.22 ASTON MARTIN LAGONDA LIMITED

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AI summary

The present invention relates to a method of manufacturing a trim component from carbon fibre comprising the steps of producing a male component with a control surface; placing unidirectional carbon fibre sheets over the control surface to define a carbon fibre layer having a thickness greater than the maximum thickness of the trim component, wherein each unidirectional carbon fibre sheet is rotated with respect to a preceding sheet such that the direction of the respective fibres of adjacent sheets misalign; curing the carbon fibre layer on the male component; removing the carbon fibre layer from the male component; securing the carbon fibre layer to a machining carriage; and, cutting the outer surface of the carbon fibre layer to expose an A surface of the trim component using a cutting tool travelling along a machining path.