Composite Panel Layup With Movable Impregnation for Continuous Production
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Solution Overview
Problem
Existing panel manufacturing processes are bulky, expensive, and time-consuming due to the separate production and assembly of composite panel components, requiring multiple machines and stages.
Innovation Solution
A compact panel manufacturing installation with a vertically movable impregnation device and guiding means, integrated on a trolley, allows continuous production of composite panels by impregnating and stacking reinforcement layers with a matrix, followed by vacuum compression and simultaneous polymerization in a heating station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate manufacturing and assembly of composite panel components is used, then manufacturing precision is maintained, but device complexity and production time increase
Solution Approach 1:
The patent combines multiple separate manufacturing operations (impregnation, guiding, stacking, and initial compression) into a single integrated installation. The impregnation device with rollers and guiding means are merged into one coordinated system that processes reinforcement layers continuously, eliminating the need for multiple separate machines while maintaining manufacturing precision through controlled integration of all functions.
Solution Approach 2:
The installation performs multiple functions simultaneously: the impregnation device applies matrix material to reinforcement layers, the guiding means directs the layers properly, and the system coordinates stacking operations. This multi-functional integration reduces device complexity while preserving the ability to manufacture high-quality composite panels with consistent precision.
2Manufacturing precision
If separate manufacturing and assembly of composite panel components is used, then manufacturing precision is maintained, but production time increases
Solution Approach 1:
The installation enables continuous production by eliminating interruptions between separate manufacturing and assembly stages. The impregnation device continuously applies matrix material to reinforcement layers as they pass through the guiding means, and stacked layers are immediately compressed and prepared for polymerization without intermediate handling, maintaining precision while dramatically reducing production time.
Solution Approach 2:
The system performs preliminary impregnation and stacking actions during the manufacturing process itself, before final polymerization. The reinforcement layers are pre-impregnated with matrix material and pre-stacked in the correct sequence within the installation, allowing subsequent polymerization to complete the process in one continuous operation rather than requiring separate post-assembly steps.
3Productivity
If integrated impregnation and guiding system is used, then productivity increases, but device complexity increases
Solution Approach 1:
The integrated system is segmented into distinct functional modules: the impregnation device with its rollers and matrix application mechanisms, the guiding means with its support rollers and alignment features, and the stacking coordination system. This segmentation allows each module to perform its function efficiently while maintaining overall system productivity, reducing the complexity burden by organizing integration into manageable segments.
4Productivity
If continuous impregnation and stacking process is used, then production time decreases, but manufacturing precision requirements increase
Solution Approach 1:
The installation incorporates feedback mechanisms to monitor and control the continuous impregnation process. The impregnation device adjusts matrix material application based on real-time conditions of the reinforcement layers passing through the guiding means, ensuring consistent impregnation quality throughout continuous production. This feedback control maintains manufacturing precision while enabling high-speed continuous operation.
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
Enables rapid and cost-effective production of large composite panels with fire-retardant properties, reducing production time and equipment footprint while maintaining quality.
Implementation Method 1
Each ply is then heated to polymerize the matrix
Implementation Method 2
impregnating a fabric reinforcement with a matrix
Implementation Method 3
the impregnation device includes a compaction device which compresses the reinforcement and the matrix after deposition of the matrix
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an apparatus (20) for manufacturing panels (10) comprising a core (12) and two plies (14) of composite material, each ply (14) of composite material comprising a reinforcement (16) impregnated with a matrix (18), the apparatus (20) comprising: - a table (22) for receiving the panel (10); - a mobile carriage (26) comprising means for guiding the reinforcement (16); - a device (38) for impregnating the reinforcement (16) with the matrix (18) in the liquid state, which device is supported by the carriage (26), the reinforcement (26) being gradually impregnated as it passes through the impregnation device (38) before it is deposited on the table (22), characterised in that the impregnation device (38) and the guide means are mounted so as to be vertically movable on the carriage (26).