Metal-Fiber Composite Roll Forming with Controlled Prepreg Viscosity
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Solution Overview
Problem
Existing methods for manufacturing fiber-reinforced metal components using prepregs with thermosetting matrices face limitations in lightweight design potential, fiber length, rigidity, and strength due to plastic deformations and delamination issues during deep drawing processes, which also affect reproducibility and cycle time.
Innovation Solution
Transferring the thermosetting matrix into a viscosity state higher than its minimum viscosity before reaching the gel point and forming it together with the metal support allows for plastic deformation and relative movements, improving reproducibility and laminate quality by enabling tight bending radii without breakage or delamination, and reducing porosity through controlled pressurization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If deep drawing process is used to form metal support with prepreg, then shaping capability is improved, but delamination and porosity increase
Solution Approach 1:
The patent applies parameter changes by controlling the viscosity of the thermosetting matrix during forming. The matrix viscosity is maintained in a specific range (10-100 Pa·s) through temperature and time control, allowing the prepreg to be formable without delamination or porosity issues that occur with conventional deep drawing processes.
2Ease of manufacture
If covering-free regions are created on metal support, then forming process capability is improved, but lightweight design potential is reduced
Solution Approach 1:
The patent applies local quality by enabling fiber reinforcement in regions that were previously left uncovered. By controlling matrix viscosity, the prepreg can be applied over entire forming surfaces including areas requiring plastic deformation, allowing continuous fiber reinforcement without compromising formability.
3Ease of manufacture
If unpressurized curing is used for prepreg, then processing simplicity is improved, but delamination and porosity increase
Solution Approach 1:
The patent applies preliminary action by pre-crosslinking the thermosetting matrix before the forming process. This preliminary crosslinking creates a gel structure that provides blocking strength, preventing delamination and porosity during subsequent forming operations, thereby eliminating the need for complex pressurized curing systems.
4Ease of manufacture
If fiber length is reduced to enable forming, then formability is improved, but rigidity and strength are reduced
Solution Approach 1:
The patent applies parameter changes by controlling matrix viscosity to enable long fiber lengths (up to several meters) to be used in the prepreg without compromising formability. The specific viscosity range (10-100 Pa·s) allows continuous or long discontinuous fibers to be processed while maintaining the mechanical properties and rigidity associated with long fiber reinforcement.
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 approach enhances the versatility and reproducibility of the method, reduces cycle time, and improves laminate quality by allowing for more efficient compaction of the matrix with the fiber structure, while avoiding costly systems engineering and maintaining adhesive strength.
Implementation Method 1
the thermosetting matrix of the prepreg is pre-cross-linked by beating
Implementation Method 2
this can not only permit a plastic deformation of the metal support in its fiber-reinforced regions
Implementation Method 3
the comparatively short exertion of force, in particular pressurization, during the deformation can be used to reduce the porosity in the fiber composite
Data Source
AI summary
A method for manufacturing a semifinished product or component is disclosed in which a metal support embodied as a split strip is covered with at least one prepreg containing a thermally cross-linkable thermosetting matrix with endless fibers, the thermosetting matrix of the prepreg is pre-cross-linked by means of heating, and the metal support covered with the pre-cross-linked prepreg is formed into a semifinished product or component by means of roll forming. In order to enable plastic deformation in fiber-reinforced regions of the metal support, it is proposed that during the pre-cross-linking of the thermosetting matrix of the prepreg, its matrix is transferred into a viscosity state that is higher than its minimum viscosity and prior to reaching its gel point, the prepreg is formed together with the metal support.