Composite Preform Figuring with Overlapping Fibers
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Solution Overview
Problem
Existing methods face challenges in shaping composite materials with large curved surfaces due to difficulties in bending flat planar fibrous preparations without forming gaps, which can reduce the strength and dimensional accuracy of the final composite material.
Innovation Solution
A preform figuring method involving a figuring die with curved surfaces, where sheet-shape fibrous preparations are stacked and bent with overlapping layers to prevent gap formation, ensuring continuous fiber reinforcement and uniform thickness, and the use of thermosetting resin impregnation and heat-curing to shape the composite material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If flat planar fibrous preparations are bent to form large curved surfaces, then the composite material can achieve curved shapes, but gaps form between layers reducing strength and dimensional accuracy
Solution Approach 1:
The fibrous preparation is divided into multiple sheet layers, with each layer being bent and positioned separately on the figuring die. This segmentation allows precise control of each layer's position and curvature, preventing gap formation while achieving the desired large curved surface shape.
Solution Approach 2:
The invention transitions from bending a single flat sheet to stacking and bending multiple sheets in three-dimensional space. By utilizing the stacking dimension, the method achieves complex curved surfaces while maintaining layer continuity and preventing gaps through overlapping edges.
2Shape
If sheet-shape fibrous preparations are stacked and bent onto curved surfaces, then curved composite materials can be formed, but fiber tension increases reducing material strength
Solution Approach 1:
Dividing the fibrous preparation into multiple sheets allows each individual sheet to be bent with smaller curvature radius, reducing the fiber tension experienced by each layer. The segmented approach distributes the bending stress across multiple layers rather than concentrating it in a single thick layer.
Solution Approach 2:
The figuring die provides a curved surface that guides the bending of each sheet layer. By using the die's curved geometry, the fibers are bent along a controlled path that minimizes excessive tension while achieving the desired curved shape.
3Manufacturing precision
If multiple sheet-shape fibrous preparations are stacked with overlapping layers, then gap formation is prevented, but the manufacturing process complexity increases
Solution Approach 1:
The fibrous preparation is segmented into multiple sheets that are stacked sequentially on the figuring die. Each sheet is positioned and bent individually, allowing precise control over layer alignment and overlap, which prevents gaps while maintaining a manageable manufacturing process.
Solution Approach 2:
The sheets are pre-cut and pre-positioned on the figuring die before bending. This preliminary arrangement of sheets with planned overlapping edges simplifies the subsequent bending process and ensures gap prevention without requiring complex real-time adjustments during manufacturing.
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 method enables the creation of composite materials with large curved surfaces without excessive fiber tension or gap formation, enhancing the strength and dimensional accuracy of the final product, particularly suitable for aircraft structural parts.
Implementation Method 1
shaping the composite material by impregnating the dry preform with the thermosetting resin and then heat-curing the thermosetting resin
Data Source
AI summary
A preform figuring method includes mounting and stacking sheet-shape fibrous preparations that have been or are yet to be impregnated with a thermosetting resin on a figuring die that has first and second figuring surfaces at least either one of which is a curved surface and making a preform for a composite material which has a curved surface that corresponds to the curved surface of the figuring die as a stack of the fibrous preparations which has layers by bending the fibrous preparations mounted on the first figuring surface onto the second figuring surface. At least a fraction of the layers that constitute the stack are formed by mounting sheet-shape fibrous preparations on the first figuring surface or the fibrous preparation adjacent in a stacking direction so that the fibrous preparations partly overlap and bending portions of the fibrous preparations mounted so as to overlap onto the second figuring surface.