Composite Fiber Curing on a Permanent Carrier Part
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Solution Overview
Problem
The manufacturing process for composite fiber products is complex and time-consuming, requiring pre-molds and multiple steps for curing, which limits production speed and assembly efficiency.
Innovation Solution
A method involving a carrier part that acts as a replica of a press tool, allowing composite fibers to be applied and cured in place, where the carrier part becomes a permanent component of the finished product, enabling continuous production without cooling the press tool and simplifying assembly by integrating the carrier with the composite fiber part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional pre-molds are used for composite fiber manufacturing, then the manufacturing process can be simplified, but the production speed is limited and assembly complexity remains high
Solution Approach 1:
The patent merges the pre-mold function with the final product carrier by integrating the composite fiber part directly onto the carrier part during curing. This eliminates the separation between temporary support structure and final product component, allowing the carrier to serve dual purposes as both manufacturing aid and functional element, thereby increasing production speed without sacrificing manufacturing simplicity
Solution Approach 2:
The carrier part is prepared in advance as a replica of the press tool with pre-defined mounting features and structural elements. By performing the carrier preparation and composite fiber application in advance on the carrier part, the actual press tool can be continuously reused without waiting for cooling or complex assembly operations, thus improving productivity
2Ease of operation
If the press tool is cooled down between curing cycles, then the composite fiber part can be removed, but production time increases
Solution Approach 1:
The patent extracts the composite fiber part from the press tool while the press tool remains heated, by removing only the carrier part with the cured composite fiber attached. This separation allows the press tool to maintain heating readiness for the next cycle without waiting for cooling, significantly reducing production time while still enabling easy removal of the product through carrier extraction
3Manufacturing precision
If multiple assembly steps are used for final product construction, then manufacturing precision can be maintained, but assembly complexity increases
Solution Approach 1:
The patent combines multiple assembly operations into a single integrated curing step. The composite fiber part is applied, positioned, and cured simultaneously on the carrier part in one continuous process, eliminating the need for separate assembly steps while maintaining precision through the structured carrier design that guides fiber placement and curing
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 approach significantly speeds up the production process, reduces assembly complexity, and allows for the creation of products with complex shapes by using the integrated carrier and composite fiber parts in subsequent steps, enhancing flexibility and reducing production costs.
Implementation Method 1
arranging the carrier part comprising the composite fiber part on the press tool; curing the composite fiber part on the carrier part
Data Source
Figure 1~2b
Figure 3~4
AI summary
A method for producing a product (200, 300, 400) comprising a composite fiber part (202, 402) and a second part (201, 401), wherein the second part (201, 401) comprises a carrier part (203, 403), wherein the carrier part (203, 403) is a replica of a press tool (301a, 301b) configured to be heated and to apply a pressure, comprising the steps of: applying (101), in a non-cured state, the composite fiber part (202, 402) on the carrier part (203, 403); arranging (103) the carrier part (203, 403) comprising the composite fiber part(202, 402) on the press tool (301a, 301b); curing (104a) the composite fiber part (202, 402) on the carrier part (203, 403); and removing (105) the product (200, 300, 400) from the press tool (301a, 301b), wherein after removal from the press tool(301a, 301b) the composite fiber part (202, 402) and the carrier part (203, 403) constitutes together at least a part of the finished product (200, 300, 400). Also disclosed is a composite fiber product comprising a composite fiber part and a second part.