Composite Ring Winding with Surface Stabilization
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Solution Overview
Problem
Existing methods for manufacturing composite materials require multiple handling operations and the use of extensive stabilizing chambers for resin solidification, which are industrially inefficient and costly.
Innovation Solution
A method involving the continuous winding of reinforcing fibers embedded in a cross-linkable resin matrix, where a superficial surface treatment creates a stable skin for self-winding into a continuous ring shape, eliminating the need for stabilizing chambers and reducing industrial costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resin-based matrix is solidified over substantial thickness using stabilizing chambers with irradiation tubes, then the composite material becomes sufficiently stabilized for handling, but the manufacturing process becomes complex and costly with extensive equipment requirements
Solution Approach 1:
The patent applies a superficial treatment only to the outer layer (5-50 μm) of the composite material surface, rather than treating the entire thickness. This localized approach creates a stable skin for handling while avoiding the need for complex stabilizing chambers that would be required to treat the full material thickness.
Solution Approach 2:
The patent uses a partial action approach by treating only the surface portion (5-50 μm) of the composite material rather than the full thickness. This partial treatment is sufficient to achieve the desired stability for handling and winding operations, eliminating the need for extensive stabilizing chambers.
2Ease of manufacture
If the composite material is cut into elementary sections and superposed in desired shape after solidification, then the final composite item can be formed, but multiple handling operations are required which reduce manufacturing efficiency
Solution Approach 1:
The patent applies the superficial stabilizing treatment during the winding process itself, before the material needs to be handled and assembled. This preliminary action allows the material to be wound directly into the final ring shape without requiring subsequent cutting and assembly operations, thereby improving both ease of manufacture and productivity.
Solution Approach 2:
The patent combines the stabilizing treatment, winding operation, and shaping process into a single integrated sequence. The superficial treatment is applied while the material is being wound onto the mandrel, merging multiple operations that would otherwise be separate into one efficient process step.
3Productivity
If a superficial treatment is applied to create a stable skin, then the tape can self-wind into a continuous ring without stabilizing chambers, but the treatment must be precisely controlled to achieve the optimal thickness
Solution Approach 1:
The patent specifies a precise parameter range for the skin thickness (5-50 μm) and uses controlled treatment parameters (UV irradiation dose, treatment time) to achieve this thickness. By optimizing these parameters, the process achieves both high productivity and the required manufacturing precision for the skin layer.
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 simplifies the manufacturing process, reduces costs, and produces high-quality composite blocks with improved mechanical properties and endurance by avoiding the capstan effect and ensuring uniform fiber distribution.
Implementation Method 1
arranging the said reinforcing fibres substantially parallel to a plane and impregnating them with the said composition in the liquid state; passing the thus obtained pre-preg through a vacuum chamber in order to remove air bubbles
Implementation Method 2
exposing the composition containing the said fibres, in a layer of a thickness less than the said given thickness, to an ionizing radiation in order partially to polymerize the resin and obtain a precomposite in which the said composition is in the solid phase
Data Source
AI summary
A process for manufacturing a composite block of closed geometry, in the form of a continuous ring, based on reinforcing fibres and on a cross-linkable resin, by continuously winding in superposition a predetermined number Nc of layers of a tape of the reinforcing fibres embedded in a matrix based on a composition comprising the cross-linkable resin, the method comprising, from the upstream end downstream, the steps of: forming a tape made of the reinforcing fibres, the thickness of the tape being between 0.1 mm and 0.5 mm; depositing the tape on a support that dictates the final shape of the composite block, and winding the tape onto the support, in a single direction, by superposing the number Nc of layers in order directly to form the continuous ring on the support, Nc being less than 15.