Composite Mold Assembly With Pliable Fiber Restraint
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Solution Overview
Problem
Existing methods for manufacturing composite parts, such as wind turbine blades, face challenges in maintaining fiber stability during the manufacturing process, particularly with fiber rovings, which tend to displace on mold surfaces, requiring complex vacuum systems that are difficult to maintain and have poor versatility.
Innovation Solution
A mold assembly with a pliable sheet that can be locally opened and closed to restrain fiber movement, using a placement head with a guide element and shoe to introduce fibers efficiently, reducing the need for vacuum systems and maintaining fiber positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If vacuum systems are used to restrain fiber displacement, then fiber stability is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts the vacuum system from the fiber placement process and replaces it with a mechanical restraint system using side walls and a movable barrier. This removes the complex vacuum infrastructure while maintaining fiber stability through physical confinement during placement.
Solution Approach 2:
The mold assembly's side walls and movable barrier automatically restrain fibers through their geometric configuration and mechanical interaction, without requiring external vacuum systems. The system serves itself by using its own structural elements to maintain fiber stability.
2Stability of the object's composition
If vacuum systems are used to restrain fiber displacement, then fiber stability is improved, but ease of operation and maintenance deteriorate
Solution Approach 1:
The patent removes the vacuum system entirely, replacing it with a passive mechanical restraint system. This eliminates the maintenance burden of vacuum pumps, seals, and control systems while improving ease of operation through simpler, more robust components.
Solution Approach 2:
The movable barrier and side walls are designed as simple, replaceable mechanical components that can be easily maintained or replaced if needed, rather than relying on complex vacuum systems that require specialized maintenance.
3Stability of the object's composition
If vacuum systems are used to restrain fiber displacement, then fiber stability is improved, but versatility decreases
Solution Approach 1:
The mold assembly with adjustable side walls and movable barrier serves multiple functions: it restrains fibers during placement, defines the placement area, and can be adapted to different fiber types and placement patterns. This universal design replaces the specialized vacuum system with a more versatile mechanical solution.
Solution Approach 2:
The movable barrier provides dynamic adaptability, allowing the placement area to be adjusted during the manufacturing process. This enables the system to accommodate different fiber dimensions and placement requirements, enhancing versatility compared to fixed vacuum systems.
4Stability of the object's composition
If pliable sheet is locally opened and closed to restrain fibers, then fiber stability is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The pliable sheet provides localized restraint where needed during fiber placement, with the ability to open and close specific areas. This creates precise local conditions for fiber stability without requiring high precision throughout the entire system, as the restraint is applied exactly where fibers are being placed.
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 mold assembly allows for stable fiber placement with reduced maintenance and complexity, enabling efficient manufacturing of tailored composite parts using fiber rovings with minimal displacement and misalignment.
Implementation Method 1
maintaining a certain tension on the pliable sheet, which can be achieved by locally opening and closing the pliable sheet
Implementation Method 2
these systems generally use a vacuum bag surrounding the fiber rovings and mold surface during roving placement
Data Source
Figure 1
Figure 2A~2B
Figure 2C~3
AI summary
The present disclosure relates to mold assemblies for manufacturing composite parts comprising fibers (202) and resin. The mold assembly comprises a mold surface (201) and a pliable sheet (210). The pliable sheet is configured to be connected to the mold surface between lateral end walls (203), and to be opened and closed locally so that the fibers can be laid in the mold. The present disclosure further relates to methods for manufacturing composite parts.