Composite Material Folding Device for Wrinkle-Free Layer Placement
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Solution Overview
Problem
The handling of fibres and yarns in composite material manufacturing is challenging due to their flexibility, leading to defects like disruption, wrinkling, and waviness, especially when handling stacks, which increases production time and costs, and requires the preliminary manufacturing of multiple fabrics with varying fibre densities.
Innovation Solution
A method involving the folding of thin material layers to create superposed portions that are oriented and layered over elements to minimize defects during the manufacturing process, allowing for the extraction of these layers to avoid wrinkles and bulges, enabling the direct contact of elements and reducing the need for preliminary fabric production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fibres and yarns are handled in their virgin flexible state, then they are easy to manipulate, but defects like disruption, wrinkling, and waviness occur frequently
Solution Approach 1:
The patent applies preliminary action by pre-coating the fibres and yarns with a sizing agent before they are handled and placed in the composite structure. This pre-treatment modifies the surface properties of the fibres, reducing their flexibility and tendency to wrinkle or disrupt during handling, thereby decreasing the defect rate while still allowing manageable operation.
2Adaptability or versatility
If multiple fabrics with varying fibre densities are manufactured preliminarily, then areas with different fibre requirements can be achieved, but production time and costs increase significantly
Solution Approach 1:
The patent applies local quality by using a single fabric layer and selectively applying additional fibres or modifying fibre distribution in specific local areas where varying density is required. This approach achieves the adaptability of having different fibre densities in different regions without the need to manufacture multiple separate fabrics, thereby maintaining high productivity.
3Adaptability or versatility
If fabrics are stacked to achieve desired fibre numbers in areas, then fibre density variations are possible, but placement must be done in sequence increasing production time
Solution Approach 1:
The patent applies merging by combining multiple fibre placement operations into a single simultaneous operation. Instead of stacking and placing multiple fabrics sequentially, the invention uses a single fabric layer with strategically placed fibres or localized fibre applications that achieve the same fibre density variation effect, thereby eliminating the time loss associated with sequential placement.
4Productivity
If a single fabric is used instead of multiple stacked fabrics, then production time is reduced, but the ability to create gradual transitions between areas with different fibre requirements is limited
Solution Approach 1:
The patent applies dynamics by using a flexible, adjustable fibre placement system that can dynamically modify fibre distribution during the single-pass placement process. This allows the system to create gradual transitions between areas with different fibre requirements by adjusting fibre placement parameters in real-time, maintaining both high productivity and adaptability.
Data Source
AI summary
A device for manufacturing a composite product has a first folded layer with a first and second superposed portion extending from a respective first and second free end to a first bend connecting the first and second superposed portions, and a second folded layer with a third and fourth superposed portion extending from a respective third and fourth free end to a second bend connecting the third and fourth superposed portions, wherein the first and second folded layers are laid adjacent to each other in order that the second portion of the first folded layer is in contact with the third portion of the second folded layer, the first and second folded layers being oriented with respect to each other in order to extend from a first side including the first, second, third and fourth free ends to a second side including the first and second bend.