Composite Surface Fibre Trimming Device
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Solution Overview
Problem
Existing methods for joining plies of fabric in composite materials, such as tufting, stitching, and Z-pinning, result in exposed through-thickness fibers that compromise the surface finish of composite components, particularly in aerospace applications, leading to inefficiencies and increased costs due to the need for additional resin layers or machining.
Innovation Solution
A fibre cutting device equipped with a cutting element and suction device is used to remove exposed portions of through-thickness fibers from the surface of composite materials, improving the surface finish by trimming or partially trimming these fibers, and an air control system maintains the cutting element's distance from the surface to minimize contact and ensure quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If through-thickness fibres are used to join plies of fabric, then structural strength is improved, but surface finish deteriorates due to exposed fibre loops and ends
Solution Approach 1:
The patent applies preliminary action by trimming the exposed fibre loops and ends before the composite material undergoes resin infusion and curing. The cutting device removes protruding fibres in advance, preventing surface defects before they become permanent, thereby eliminating the need for additional resin layers or post-moulding machining operations.
Solution Approach 2:
The patent segments the surface treatment process by separating the fibre trimming operation from the main composite manufacturing process. The cutting device independently addresses surface irregularities caused by through-thickness fibres, allowing the resin infusion and curing processes to proceed without interference from exposed fibre loops and ends.
2Manufacturing precision
If additional resin layers are applied to cover exposed fibres, then surface finish is improved, but component weight increases
Solution Approach 1:
The patent prevents the need for additional resin layers by performing preliminary trimming of exposed fibres before resin infusion. By removing fibre loops and ends in advance, the surface is prepared to accept resin evenly without requiring extra material to cover defects, thereby avoiding weight increase.
Solution Approach 2:
The patent extracts the problematic exposed fibre loops and ends from the composite surface using the cutting device. By removing these protruding fibres before resin application, the surface is left clean and ready for resin infusion, eliminating the need to add extra resin layers to cover defects.
3Manufacturing precision
If post-moulding machining is performed to remove surface irregularities, then surface finish is improved, but production cost and lead time increase
Solution Approach 1:
The patent performs the fibre trimming operation preliminarily, before resin infusion and curing, rather than as a post-moulding machining step. This preliminary action eliminates surface irregularities in advance, avoiding the need for time-consuming post-moulding machining operations and reducing overall production lead time.
Solution Approach 2:
The patent skips the post-moulding machining step entirely by performing fibre trimming before resin infusion. The cutting device rapidly removes exposed fibres in advance, allowing the manufacturing process to proceed directly to resin infusion and curing without the intermediate step of post-moulding surface correction.
4Ease of manufacture
If stitching is used to join plies, then ease of manufacture is improved, but fibre strength is reduced due to curvature and locking points
Solution Approach 1:
The patent extracts and removes the problematic stitching process entirely, replacing it with through-thickness fibres that are pushed directly through the plies without creating loops or locking points. This extraction of the stitching method eliminates the curvature-induced strength reduction while maintaining ease of manufacture through alternative joining techniques.
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
The fibre cutting device enhances the surface finish of composite materials, reducing weight and production costs by eliminating the need for additional resin layers and minimizing residual stress-induced surface irregularities, while maintaining the structural integrity of high-strength fibers.
Implementation Method 1
a suction device which is operable to extract the cut exposed portions from the surface of the composite material
Data Source
AI summary
A fiber cutting device and method for cutting one or more exposed portions of a through-thickness fiber in a surface of a composite material, the device including: a cutting element for cutting the one or more exposed portions; a suction device which is operable to extract the cut exposed portions from the surface of the composite material; and a storage device for receiving the cut exposed portions.