Composite Stitching Machine with Pneumatic Fiber Supply

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for manufacturing composite materials, such as three-dimensional braiding and stitching, face limitations in product size, time consumption, and fiber damage, particularly when using high-strength carbon fibers, which weakens the z-direction strength of composite materials.

Innovation Solution

A sewing machine that automatically and continuously stitches composite materials using high-rigidity fibers, featuring a stitching needle with pneumatic fiber supply, a vertical conveying head unit for reciprocating motion, and a fiber cutting unit to minimize fiber damage, allowing fibers to be bent at 90 degrees or less for enhanced z-direction reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional stitching method with continuous twisting of upper and lower threads is used, then soft fibers can be stitched, but high-rigidity carbon fibers cannot exhibit sufficient strength because the stitched fibers are damaged

Engineering Contradiction:

Improvez-direction strength of composite materialVSAvoidfiber damage during stitching

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Instead of continuously twisting and bending the fiber at 180 degrees as in traditional stitching, the invention inverts the approach by allowing the fiber to pass through the workpiece in a straight line with bending angles of 90 degrees or less, thereby preventing fiber damage while maintaining stitching functionality

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention changes the critical parameter of fiber bending angle from 180 degrees in traditional stitching to 90 degrees or less, which fundamentally alters the stress state on the fiber and enables high-rigidity carbon fibers to maintain their strength properties after stitching

Inventive Principle:

Principle #35Parameter changes

2Strength

If three-dimensional braiding or weaving process is used to obtain structure in thickness direction, then fiber reinforcement is achieved, but product size is limited and manufacturing time is excessive

Engineering Contradiction:

Improvez-direction reinforcementVSAvoidmanufacturing time and product size capability

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The invention segments the three-dimensional reinforcement process into discrete stitching points rather than requiring continuous three-dimensional braiding or weaving, allowing the process to be applied to large structures without excessive time consumption

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses stitching as an intermediary method to achieve three-dimensional reinforcement effects without requiring the complex and time-consuming three-dimensional braiding or weaving processes, thereby improving productivity while maintaining structural integrity

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If Z-pinning technology is used to insert metal pins or cured composite pins, then physical properties in z-direction are slightly increased, but large amount of time and effort is required

Engineering Contradiction:

Improvez-direction physical propertiesVSAvoidtime and effort for pin insertion

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The invention uses disposable stitching needles that penetrate and withdraw once, eliminating the need for time-consuming insertion and securing processes required by Z-pinning technology, thereby significantly improving productivity while achieving similar reinforcement effects

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

The sewing machine reduces process time, improves productivity, and minimizes fiber damage, enabling the effective use of high-strength carbon fibers for enhanced z-direction strength in composite materials.

Implementation Method 1

a stitching needle having a hollow interior which is connected to a fiber storage reel to be supplied with the fiber and extend the fiber to the other end by pneumatic pressure

Methodology Applied

Scientific EffectPneumatic pressure: Pressure Increase

Data Source

PatentUS10883211B2Sewing machine for stitching composite materials

Publication Date: 2021.01.05 INDUSTRYACADEMIC COOPERATION FOUNDATION GYEONGSANG NATIONAL UNIVERSITY

AI summary

The present invention relates to a structure for fastening composite structures, and more particularly, to a sewing machine for stitching composite materials which is capable of automatically and continuously stitching the composite structures by using a high-rigidity fiber in order to laminate and join the composite materials. The sewing machine for stitching composite materials according to the present invention automatically and continuously performs a stitching operation for joining composite materials by using a high-rigidity composite fiber for joining the composite materials, and as a result, it is possible to reduce process time for joining the composite materials and improve productivity.