Charge Air Pipe Production Using Braided Thermoplastic Fibers
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Solution Overview
Problem
Current methods for producing charge air pipes, such as blow molding and fiber-reinforced extrusion, face issues like high waste, uneven wall thickness, complex multi-stage processes, and limited fiber choices, which hinder the achievement of uniform wall thickness and precise inner contours necessary for thermo-mechanical requirements in compact engine designs.
Innovation Solution
A method involving braiding a pipe contour on a core using continuous thermoplastically deformable fibers, placing the fiber braid in a mold, heating to melt the thermoplastic fibers, cooling under pressure, and removing the component, which allows for a uniform wall thickness and precise inner contour using a compressible core and automated braiding, enabling the use of hybrid yarns with various reinforcing fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If blow molding process is used to produce charge air pipes, then production is simple, but wall thickness becomes uneven and material waste increases
Solution Approach 1:
The invention separates the reinforcement function from the matrix material function by using discrete reinforcement elements (fibers, meshes, or preforms) combined with a thermoplastic matrix. This segmentation allows independent optimization of structural reinforcement and material distribution, enabling uniform wall thickness while maintaining production simplicity.
Solution Approach 2:
The reinforcement structure is prepared in advance as separate components (fibers, meshes, or preforms) before being combined with the thermoplastic matrix. This preliminary preparation of reinforcement elements allows for precise placement and configuration, ensuring uniform wall thickness and structural integrity without complicating the overall manufacturing process.
2Manufacturing precision
If fiber-reinforced plastics are used to avoid blow molding disadvantages, then wall thickness uniformity improves, but manufacturing process complexity increases
Solution Approach 1:
The invention utilizes the thermoplastic nature of the matrix material, which can be transformed between solid and molten states. By heating the thermoplastic matrix to a molten state during forming, the material becomes flowable and can be easily molded around the reinforcement structure, then solidifies upon cooling. This parameter change simplifies the manufacturing process while maintaining wall thickness uniformity.
Solution Approach 2:
The invention combines reinforcement materials (fibers, meshes, or preforms) with a thermoplastic matrix material to create a composite structure. This composite approach allows the reinforcement to provide structural strength and wall thickness control, while the thermoplastic matrix provides ease of processing and forming, thereby reducing overall manufacturing complexity.
3Adaptability or versatility
If multi-stage manufacturing process is used for fiber-reinforced charge air pipes, then production flexibility increases, but manufacturing time and complexity increase
Solution Approach 1:
The invention merges the reinforcement structure and matrix material forming into a single integrated manufacturing step. The reinforcement elements (fibers, meshes, or preforms) are placed in the mold cavity, and the thermoplastic matrix is then molded around them in one continuous process. This eliminates the need for separate reinforcement application steps, reducing manufacturing time while maintaining production flexibility.
Solution Approach 2:
By utilizing the thermoplastic material's ability to change state between solid and molten, the invention enables a single-step forming process where the thermoplastic matrix is molded around the reinforcement structure in its molten state and then solidifies. This parameter change allows complex geometries to be produced in one step without requiring multiple discrete manufacturing operations.
4Reliability
If minimum wall thickness is guaranteed in bending areas, then thermo-mechanical requirements are met, but material consumption increases
Solution Approach 1:
The invention applies reinforcement materials specifically in areas where structural strength is needed, such as bending areas and high-stress zones. The reinforcement elements (fibers, meshes, or preforms) are strategically positioned to provide localized strengthening, allowing the wall thickness to be optimized locally rather than uniformly throughout the entire pipe. This reduces overall material consumption while ensuring thermo-mechanical requirements are met in critical areas.
Solution Approach 2:
By combining reinforcement materials with the thermoplastic matrix in a composite structure, the invention achieves high structural strength with reduced material usage. The reinforcement elements provide the necessary mechanical properties in critical areas, allowing the overall wall thickness to be minimized while still meeting thermo-mechanical requirements, thereby reducing material waste.
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 method produces charge air pipes with a uniform wall thickness and precise inner contour, reducing material waste and complexity, while allowing for adaptable fiber choices and automated production, enhancing thermo-mechanical performance and manufacturing efficiency.
Implementation Method 1
heating the mold in such a way that the thermoplastic continuous fibers melt
Implementation Method 2
cooling the mold while applying pressure in the mold
Data Source
Figure 1
AI summary
The invention relates to a method for producing a charge air pipe from plastic. The object of the invention is to create a method for producing charge air pipes, by means of which charge air pipes can be produced from continuous fibre-reinforced plastics (3, 4) with equal wall thickness and a high-precision inner contour. In this method, a charge air pipe is created having a reinforced thermoplastic matrix as a wall. Advantages of a thermoplastic matrix are a higher degree of familiarity in terms of processing, as well as the possibility of connecting additional connection and functional elements, e.g. holders, made of a thermoplastic synthetic material, to the component by means of a welding method, among others.