Composite Fiber Plating Control via Helical Link Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing composite material parts with reinforcing fibers struggle to achieve optimal plating on a mandrel, leading to inconsistent geometrical conformity and fiber distribution, which affects the mechanical strength-to-mass ratio and is challenging to control in an industrialized context.
Innovation Solution
The method involves winding a link, such as a ribbon or thread, around the layers of reinforcing fibers on the mandrel to enhance plating control, which can be done manually or with an apparatus, and incorporating calendering operations to ensure regular fiber orientation and minimize stress, thereby improving the adherence and cohesion of the fiber layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the layers of reinforcing fibers are applied to the mandrel using traditional braiding or manual methods, then the manufacturing process can be completed, but the plating control is insufficient leading to inconsistent geometrical conformity and fiber distribution
Solution Approach 1:
A linking element is introduced as an intermediary between the braiding machine and the mandrel. This link wraps around the layers of fibers during braiding to mechanically couple them to the mandrel, ensuring consistent plating and geometrical conformity without requiring complex direct control mechanisms
Solution Approach 2:
The linking element is pre-positioned or pre-wrapped around the fiber layers before the braiding process completes. This preliminary action ensures that the fibers are already properly coupled to the mandrel geometry, preventing plating inconsistencies that would otherwise require complex real-time control
2Manufacturing precision
If the tension of the reinforcing fibers is varied to optimize plating, then the geometrical conformity improves, but the fiber orientation and speed of progression must be precisely controlled
Solution Approach 1:
The linking element serves as a mechanical intermediary that automatically translates mandrel geometry into consistent fiber tension and orientation. This eliminates the need for operators to manually control multiple parameters (tension, orientation, speed) as the link inherently maintains proper fiber- mandrel coupling throughout the braiding process
3Ease of manufacture
If manual methods are used to apply fabric or pre-impregnated drapes, then the process can be completed, but the plating control depends on operator know-how making industrialization risky
Solution Approach 1:
The linking element creates a self-regulating system where the mechanical coupling between the link, fiber layers, and mandrel automatically ensures consistent plating. The system serves itself by using the inherent geometry of the components to maintain proper fiber distribution and adhesion without requiring skilled operator intervention, enabling reliable industrialization
Solution Approach 2:
The linking element acts as a standardized intermediary component that replaces operator skill with a mechanical solution. This intermediary ensures consistent plating results regardless of operator expertise, making the process suitable for industrialized manufacturing where reliability and repeatability are critical
Data Source
Figure 1~3
Figure 4~7
Figure 8~11
AI summary
The invention relates to a method for manufacturing a part made of a composite material, wherein one or more layers (17) of braided or woven or even draped reinforcing fibers (4) are applied to a mandrel having an overall rotationally symmetrical shape. After one or more layers (17) have been applied to the mandrel (2), an operation is carried out for winding at least one tie (7), which is helically wound around and along the assembly (6) consisting of the mandrel (2) and each layer (17) of reinforcing fibers (4) that said mandrel supports, in order to clamp each layer (17) of reinforcing fibers against said mandrel (2). The invention relates to the manufacture of parts made of a composite material, such as carbon beams, connecting rods or even arms.