Composite Component Indicator Layers Repair Visualization
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Solution Overview
Problem
Composite structures made from glass fibre rovings are difficult to repair as the randomized fibre positioning makes it challenging to visualize and quantify the amount of fibre material removed during abrasion, unlike structures made from fibre mats where edge-rings indicate the number of layers removed.
Innovation Solution
Incorporating visual indicator layers, such as differently colored dye or sewing threads, between layers of fibre roving material to create a composite component that allows for easy visualization of fibre material removal during repair, similar to structures made from fibre mats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fibre rovings are used instead of fibre mats, then the composite structure achieves better mechanical properties and random fibre distribution, but the ability to visualize and quantify fibre material removal during repair is lost
Solution Approach 1:
The patent applies color changes by introducing indicator layers with contrasting colors (such as white or colored threads, dye-impregnated layers) between the glass fibre roving layers. These indicator layers create visible edge-rings during abrasion similar to annual rings in trees, enabling easy visualization and quantification of fibre material removal while maintaining the structural advantages of random fibre distribution in roving-based composites
2Ease of repair
If fibre mats are used instead of glass fibre rovings, then the visualization of fibre layers during repair is easier, but the mechanical properties and random fibre distribution are compromised
Solution Approach 1:
The patent applies composite materials by combining glass fibre rovings (which provide superior mechanical properties and random fibre distribution) with indicator layers (such as contrasting colored threads, dye-impregnated materials, or woven mats with different fiber orientations). This hybrid composite structure maintains the mechanical advantages of roving-based composites while introducing visual indicators that enable easy assessment of fibre material removal during repair
3Ease of repair
If indicator layers are introduced between roving layers, then the visualization of fibre material removal is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the composite structure into distinct layers separated by indicator layers. This segmentation approach allows the indicator layers to be easily introduced at specific intervals during the manufacturing process (e.g., every n-th layer) and provides clear visual markers for assessing fibre material removal without requiring complex manufacturing equipment or processes
Data Source
Figure 1~4
AI summary
A method for manufacturing a composite component (5) is disclosed. It comprises the steps of a) placing fibre rovings (3) in a mould until a particular thickness of fibre roving material is reached, b) placing an indicator layer (4) onto the roving material (3), c) placing fibre rovings (3) onto the indicator layer until a particular thickness of fibre roving material is reached, d) repeating the steps b) and c) until a predetermined final thickness of fibre roving material is reached, and e) casting the composite component (5).