Carbon Fiber Tow Volumization for Uniform Textile Densification
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Solution Overview
Problem
Existing methods for fabricating carbon/carbon brake disks face challenges in achieving uniform fiber distribution and maintaining fiber volume during the textile process, leading to heterogeneous densification and poor fiber coverage, especially when using carbon fiber tows that tend to neck down and form oval shapes under tension.
Innovation Solution
An air jet device is used to manipulate and volumize carbon fiber tows, increasing fiber spacing and stability, while minimizing tension and fiber damage, to facilitate more homogeneous fiber distribution and densification, allowing for the fabrication of low areal weight fabrics with full fiber coverage and improved composite properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If carbon fiber tows are subjected to tension during textile processing, then the tows can be transported and positioned, but the tows neck down and form oval shapes leading to heterogeneous fiber distribution
Solution Approach 1:
The patent introduces a volumized tow configuration that adds a third dimension (volume expansion) to the traditional flat tow structure. This volumized state allows the tow to be handled and positioned more easily while maintaining fiber linearity and preventing necking, as the three-dimensional configuration reduces tension-induced deformation.
Solution Approach 2:
The patent changes the physical state parameter of the fiber tow from a dense, flat configuration to a volumized, expanded configuration. This parameter change in tow morphology allows for improved handling characteristics and prevents the necking phenomenon that occurs with traditional tension-based transport methods.
2Quantity of substance
If carbon fiber tows are densely packed to maintain fiber volume, then material efficiency is improved, but fiber coverage becomes poor and porosity increases
Solution Approach 1:
The volumized tow configuration transforms the fiber arrangement from a two-dimensional flat pack to a three-dimensional expanded structure. This dimensional change allows fibers to be distributed more uniformly across the fabric area, improving coverage while maintaining appropriate volume utilization through the expanded configuration.
3Ease of operation
If mechanical tension is applied to carbon fiber tows for processing, then the tows can be manipulated and positioned, but fiber damage occurs and fiber quality deteriorates
Solution Approach 1:
The patent employs pneumatic methods to manipulate and position the volumized tows without applying direct mechanical tension to the fibers. This pneumatic handling approach maintains fiber integrity while enabling effective manipulation and positioning during the textile processing operation.
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
The air jet manipulation results in a more uniform fiber distribution and reduced porosity, enhancing the homogeneity and mechanical properties of carbon/ceramic composites, particularly in high-temperature applications like friction disks and gas turbine components.
Implementation Method 1
An air jet device is used to manipulate and volumize carbon fiber tows, increasing fiber spacing and stability, while minimizing tension and fiber damage
Data Source
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AI summary
A transport of carbon fiber bundles (150), in as fabricated carbon fiber tow form (245, 250, 255, 260, 265; 500, 505), with in-line manipulation of the fiber bundles (150) (spreading or spreading and volumization with manipulators) during fiber bundle transport is described herein. A method including positively transporting and placing a fiber bundle (150) via a moveable fiber bundle delivery mechanism (130; 130A, 130B) interposed between a fiber bundle supply (150) and a fiber bundle delivery location, manipulating at least one of a fiber volume and an areal weight of the fiber bundle via an air jet device (111; 611, 612) coupled between the fiber bundle delivery location and the fiber bundle supply (150), and controlling delivery of the fiber bundle tension from the fiber supply (150) through an electronic unwinder (115) is also described.