Composite Shaft Fiber Placement for Faster Axial Reinforcement
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Solution Overview
Problem
The formation of composite shafts is slow and costly due to the time-consuming application of layers and challenges in manufacturing shafts that experience axial loads, as existing methods face difficulties in efficiently placing axially-dominated fibers using filament winding.
Innovation Solution
An apparatus and method involving an axial fiber strip dispensing assembly and a hoop fiber strip dispensing assembly, which include fiber strip guides and consolidation elements to dispense and orient fibers circumferentially and axially, applying heat and pressure to bond the fibers in a composite structure, allowing for efficient layering and improved axial loading capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layers of composite are applied one strip at a time using traditional filament winding, then the manufacturing process can handle axial loading requirements, but the production speed is slow and costly
Solution Approach 1:
The apparatus segments the fiber placement process by using multiple independent dispensing assemblies (first hoop fiber strip dispensing assembly, second hoop fiber strip dispensing assembly, and axial fiber strip dispensing assembly) that can operate simultaneously to place different fiber orientations (hoop and axial) in parallel, thereby increasing production speed while maintaining the ability to meet axial loading requirements through proper fiber orientation placement
Solution Approach 2:
The invention transitions from traditional single-direction filament winding to a multi-dimensional fiber placement approach by simultaneously dispensing hoop fibers (circumferential direction) and axial fibers (lengthwise direction) using separate dispensing assemblies, enabling efficient placement of axially-dominated fibers while improving overall manufacturing efficiency
2Productivity
If multiple fiber strips are dispensed simultaneously to improve production speed, then productivity increases, but device complexity increases
Solution Approach 1:
Each dispensing assembly is designed as a multi-functional unit that can dispense multiple fiber strips simultaneously (e.g., the axial fiber strip dispensing assembly dispenses both first and second axial fiber strips), reducing the total number of separate assemblies needed and managing system complexity while maintaining high productivity
Solution Approach 2:
The apparatus uses a shaft support assembly as an intermediary component that coordinates the movement and positioning of multiple dispensing assemblies, managing the complexity of simultaneous multi-directional fiber placement through a centralized control mechanism that synchronizes hoop and axial fiber dispensing
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 enables the rapid and cost-effective formation of composite shafts with enhanced axial loading capabilities by efficiently dispensing and consolidating fiber strips, overcoming manufacturing challenges and reducing production time.
Implementation Method 1
coupling the first portion of the plurality of axial fiber strips to the shaft base by applying heat and radially inward pressure to the first portion of the plurality of axial fiber strips
Implementation Method 2
coupling the first portion of the plurality of axial fiber strips to the shaft base by applying heat and radially inward pressure to the first portion of the plurality of axial fiber strips
Data Source
AI summary
An apparatus for forming a composite shaft may comprise an axial fiber strip dispensing assembly and a hoop fiber strip dispensing assembly. The axial fiber strip dispensing assembly may include a plurality of fiber strip guides located circumferentially about a center axis. The plurality of fiber strip guides may be configured to dispense a plurality of circumferentially adjacent first fiber strips with the plurality of circumferentially adjacent first fiber strips extending in a generally axial direction. The hoop fiber strip dispensing assembly may be configured to dispense a second fiber strip circumferentially about the center axis.