Commingled Fiber Preform for Resin Transfer Molding
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Solution Overview
Problem
The existing methods for producing composite components, particularly in the automotive and transportation industries, face inefficiencies in preform production and high scrap rates due to the slow and error-prone process of forming preforms by compressing chopped fibers and laying up woven fabric, which hinders the widespread adoption of lightweight carbon fiber reinforcement over glass fiber due to cost and handling issues.
Innovation Solution
A method involving the selective stitching of commingled fiber bundles onto a substrate to form a multilayer preform, allowing for the efficient creation of lightweight, high-strength composite materials by using a combination of carbon, glass, and aramid fibers, with the ability to vary fiber orientations and compositions, reducing waste and improving handling through automated sewing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If preforms are formed by compressing chopped fibers or laying up woven fabric, then the preform structure can be created, but the production speed is slow and the process is error-prone
Solution Approach 1:
The fiber bundles are pre-cut to the exact lengths needed for specific locations in the preform, and pre-arranged in bundles with predetermined orientations. This preliminary preparation eliminates the need for slow, error-prone on-site fiber placement during molding, as the fibers are already positioned and oriented correctly before being inserted into the mold.
Solution Approach 2:
The fiber reinforcement is divided into separate bundles, each containing fibers of specific lengths and orientations tailored for particular regions of the final product. This segmentation allows different fiber bundles to be independently prepared and inserted into their precise locations, improving both production speed and placement accuracy compared to handling individual chopped fibers or large woven fabrics.
2Weight of moving object
If carbon fiber is used to replace glass fiber, then the component weight is reduced and strength is improved, but the cost increases
Solution Approach 1:
Different fiber bundles with specific carbon fiber concentrations are used in different regions of the preform based on local structural requirements. Areas requiring higher strength and stiffness receive bundles with higher carbon fiber content, while less critical areas use bundles with lower carbon fiber content or different fiber compositions entirely. This localized optimization reduces overall material cost while maintaining necessary performance characteristics.
Solution Approach 2:
The invention uses composite fiber bundles containing multiple types of fibers (carbon, glass, aramid) in specific ratios within each bundle. This allows the preform to incorporate the high strength-to-weight ratio of carbon fiber where needed, while using more cost-effective glass or aramid fibers in other regions, thereby reducing overall manufacturing cost while still achieving weight reduction and strength improvement.
3Ease of manufacture
If preforms are formed by compressing chopped fibers, then the preform can be created, but the handling difficulty increases and scrap is produced
Solution Approach 1:
Fiber bundles are pre-cut to exact lengths and pre-arranged in correct orientations before being inserted into the mold. This preliminary preparation eliminates the need for subsequent cutting, trimming, or modification of the preform after molding, thereby reducing scrap material and improving handling efficiency since the bundles are already in their final configuration.
Solution Approach 2:
By dividing the fiber reinforcement into pre-configured bundles with specific lengths and orientations, the invention eliminates the need to handle and position individual chopped fibers or large sheets of woven fabric. The bundled format improves handling ease while the precise pre-cutting eliminates scrap generation from excessive fiber length or misalignment.
Data Source
AI summary
A fiber preform for use in a resin transfer molding or liquid composite molding process and process of making the same are provided. The preform includes a substrate, a fiber bundle arranged on the substrate in a predetermined pattern and attached to the substrate by a plurality of stitches of a thread. The fiber preform is capable of being pre-formed into a three-dimensional shape. The fiber preform along with a sheet of preformed thermoset resin that impregnates at least a portion of the fiber preform forms a composite material. The fiber preform reinforces areas of stress concentration of a core to form a vehicle component.