Composite Framework Pultrusion Method

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for producing three-dimensional frameworks are laborious and expensive due to the need for extensive arrangement and movement of pre-produced rods, which increases production costs and technical effort.

Innovation Solution

A method involving pultrusion and extrusion of composite material rods directly at required positions within the framework, eliminating the need for rod rearrangement, with continuous production and node connection using a pultrusion unit and extrusion unit moved along a straight path, forming rods without hinges and with fibers and matrix distribution for enhanced load-bearing capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If rods are produced separately and then arranged at required positions, then rods can be manufactured with standard processes, but production becomes laborious and expensive due to extensive arrangement work

Engineering Contradiction:

Improverod manufacturingVSAvoidframework production efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent combines the rod production process with the framework assembly process by moving the pultrusion unit along a movement path that traces the required positions of rods in the final framework. This merges manufacturing and assembly into a single continuous operation, eliminating the laborious arrangement step while maintaining standard rod production capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pultrusion unit performs preliminary positioning of rods at their final locations within the framework during the production process itself. By pre-positioning rods at their required positions as they are being manufactured, the need for subsequent arrangement operations is eliminated, thereby improving productivity without compromising manufacturing ease.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If rods are produced and then moved to required positions, then standard production processes can be used, but production costs increase due to additional arrangement operations

Engineering Contradiction:

Improveproduction process simplicityVSAvoidproduction system complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent introduces dynamic positioning capability to the pultrusion unit by enabling it to move along a flexible movement path that adapts to the required rod positions in the framework. This dynamic adjustment eliminates the need for complex separate arrangement operations while maintaining production process simplicity, as the same unit performs both manufacturing and positioning functions.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If framework is produced by assembling pre-produced rods, then modular production is possible, but labor effort and production time increase significantly

Engineering Contradiction:

Improvemodular production capabilityVSAvoidproduction time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent implements continuous production by moving the pultrusion unit along a continuous movement path that produces rods at their final positions without interruption. This continuous operation eliminates the time loss associated with separate assembly operations, as rod production and framework formation occur simultaneously in one uninterrupted process, while still allowing modular production of individual rod sections.

Inventive Principle:

Principle #20Continuity of useful action

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 reduces production costs and labor by producing rods in situ, resulting in a lightweight framework with high load-bearing capacity and low bending moments, achieved through continuous pultrusion and extrusion processes and material-locking connections.

Implementation Method 1

producing the rods out of a composite material with fibers and a matrix, which are connected with nodes to at least one other rod and/or another component, comprising the steps of: producing the rods out of a composite material, connecting the rods with at least one other rod and/or another component at the nodes, whereby the rods are being produced with pultrusion and/or extrusion

Methodology Applied

Scientific EffectPultrusion:

Implementation Method 2

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 3

continuous pultrusion and extrusion processes and material-locking connections

Methodology Applied

Scientific EffectMaterial-locking:

Data Source

PatentUS10384387B2Method for producing a framework

Publication Date: 2019.08.20 9T LABS AG

AI summary

With a method for producing a two-dimensional or three-dimensional framework (1) with rods (2) of a composite material with fibers and a matrix, which are connected with nodes (3) to at least one other rod (2) and/or another component (29), comprising the steps of: producing the rods (2) out of a composite material, connecting the rods (2) with at least one other rod (2) and/or another component (29) at the nodes (3), the framework (1) should be manufactured inexpensively and reliably by a low technical effort.This object can be solved in a way that the rods (2) are being produced with pultrusion and/or extrusion and a pultrusion unit (6) and/or an extrusion unit (7) is moved in space such that after the pultrusion and/or extrusion the pultruded and/or extruded rods (2) are pultruded and/or extruded in each case at the required position within the framework (1).