Composite Laminate Layer Separation for Wrinkle-Free Bending
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Solution Overview
Problem
Existing methods for forming composite materials face challenges such as the occurrence of wrinkles, increased number of steps and labor for alignment, and difficulty in forming due to high frictional forces between the sheet and the laminate.
Innovation Solution
A composite material is formed by laminating fiber sheets and separating the laminate into multiple layers along the plate thickness direction in the region to be bent, allowing for sequential layer-by-layer bending to prevent wrinkles and alignment issues, while using a release material to reduce friction and facilitate forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the plate thickness of the laminate is increased, then the structural strength is improved, but wrinkles are generated in the composite material during forming
Solution Approach 1:
The patent divides the thick laminate into multiple sub-laminates with smaller plate thicknesses. Each sub-laminate can be formed separately without generating wrinkles, while the final assembled structure maintains the required structural strength. This segmentation allows the laminate to be processed in manageable layers that can be sequentially formed and then bonded together.
Solution Approach 2:
The patent introduces a new dimension of assembly by stacking multiple sub-laminates in the thickness direction. Instead of forming one thick laminate, the solution forms multiple thin laminates and combines them through bonding, effectively solving the wrinkle problem while maintaining structural integrity through the multi-layer configuration.
2Manufacturing precision
If a plurality of laminates are sequentially laminated and press-formed, then the plate thickness is controlled, but the number of steps increases and alignment becomes difficult
Solution Approach 1:
The patent applies preliminary action by providing release sheets between sub-laminates before forming. These release sheets facilitate easy separation and alignment during the forming process, reducing the complexity of sequential operations. The release sheets are prepared in advance and integrated into the laminate structure before forming begins.
Solution Approach 2:
The patent uses release sheets as intermediary elements between sub-laminates. These intermediaries enable controlled separation and reassembly during the forming process, making alignment easier and reducing the number of manual intervention steps required when handling multiple laminates sequentially.
3Ease of operation
If sheets are pulled out while applying pressure for forming, then the sheets are positioned, but friction between the sheet and laminate increases making pulling out difficult
Solution Approach 1:
The patent introduces release sheets as intermediary elements between the pulling-out sheet and the laminate. These release sheets have low friction properties that reduce the frictional force during the pulling-out operation, allowing sheets to be positioned and extracted more easily without requiring excessive force.
Solution Approach 2:
The patent changes the friction parameter by introducing release sheets with specifically engineered surface properties. These release sheets modify the interface characteristics between layers, reducing the coefficient of friction and enabling easier sheet manipulation during forming and extraction operations.
Data Source
AI summary
A composite material includes a laminate in which fiber sheets are laminated. The laminate has a bendable portion that is to be bent along a mold. In a region of the laminate from an end edge on a bent side to the bendable portion, the laminate is divided into layers along a plate thickness direction of the laminate.