Composite Parts Braided Covering Variable Thickness
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Solution Overview
Problem
Existing methods for manufacturing composite parts with braided coatings struggle to achieve significant variations in thickness, as braiding processes are limited in accommodating large thickness changes, and previous reinforcement methods result in rigid parts.
Innovation Solution
A method involving the production of a mandrel, braiding a coating around it, applying locally deformable fiber patches to achieve desired shapes, repeating these steps, and finally braiding an outer covering, with resin infusion and polymerization to create parts with variable thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If braiding speed is reduced to increase coating thickness, then thickness is marginally increased, but productivity decreases and significant thickness variations cannot be achieved
Solution Approach 1:
The coating is divided into multiple discrete fiber patches applied at different locations and thicknesses, rather than attempting to create variable thickness through continuous braiding. Each patch can be independently sized and positioned to achieve the desired local thickness variation without affecting overall production speed.
Solution Approach 2:
The solution transitions from controlling thickness through the braiding process parameters (speed, tension) to applying discrete patches in the spatial dimension. This allows thickness variation to be achieved by adding material at specific locations rather than modifying the braiding process continuously.
2Strength
If manual or robotic insertion of flat reinforcing bodies is used, then local reinforcement is achieved, but the parts become very rigid and lose flexibility
Solution Approach 1:
The reinforcing elements are changed from rigid flat fabric layers to flexible three-dimensional random fiber patches. This parameter change in the physical state and structure of the reinforcement material allows local strength enhancement while preserving the flexibility and deformability needed for complex shape formation.
Solution Approach 2:
The invention combines braided fiber structures with randomly oriented fiber patches to create a composite reinforcement system. The braided structure provides overall form and flexibility, while the random fiber patches provide localized reinforcement, creating a synergistic composite material system that achieves both strength and flexibility.
3Shape
If pre-impregnated unidirectional fabrics are used for patches, then shaping is improved, but deformability may be reduced
Solution Approach 1:
The fiber patches are pre-impregnated with resin and partially shaped before application, but this preliminary action is controlled to maintain sufficient deformability. The pre-shaping prepares the patches for their final position while the resin impregnation is optimized to allow further deformation during the forming process without complete rigidification.
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 creation of parts with localized extra thicknesses and flexible shapes, allowing for softer mandrel forms to be scaled up by stacking deformable fabric patches, resulting in parts with customizable thickness and reduced risk of delamination.
Implementation Method 1
supply of resin and polymerization thereof
Data Source
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AI summary
The invention relates to a method for producing a part from a composite material, comprising the following steps: production of a mandrel; braiding of a fiber covering (11) around the mandrel, following the shape of the mandrel as closely as possible; local application on the braided covering of at least one fibre patch (12a, 12b, 12c), each patch being formed such that it is sufficiently deformable to closely follow the contour of the braided covering or patch on which it is applied; repetition of the two braiding and patch application steps as many times as necessary in order to obtain the preform; introduction of resin into the preform and polymerisation thereof.