Continuous Carbon Fiber Structures Using Push-Through Mandrel Molding
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Solution Overview
Problem
Conventional manufacturing methods for carbon fiber structures face limitations in producing ultra-lightweight structures with diverse shapes and thicknesses, as they require high-temperature annealing processes and are restricted by the use of thicker fibers due to pulling forces, hindering efficient production of continuous carbon fiber structures with complex shapes and high volume requirements.
Innovation Solution
A method involving a system with inner and outer mold segments mounted on a rod, where motors spin the rod and mandrel to wind carbon fiber threads, applying heat and pressure to form continuous carbon fiber structures of varying shapes and sizes, allowing for automated and continuous manufacturing without pulling stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pultrusion method is used to manufacture carbon fiber structures, then continuous production is achieved, but the structural thickness is limited to a minimum of 1 mm due to pulling force restrictions
Solution Approach 1:
Instead of pulling the carbon fiber structure through a die (pultrusion), the invention inverts the approach by pushing/forcing the structure through the die using a mandrel that advances from within, eliminating the pulling force limitation and enabling production of structures thinner than 1 mm
2Reliability
If high-temperature annealing processes are used, then carbon fiber-reinforced composites are produced, but manufacturing complexity and cost increase
Solution Approach 1:
The invention changes the thermal processing parameters by using low-temperature thermosetting resins (curing at room temperature or moderate temperatures) instead of high-temperature annealing, thereby producing carbon fiber-reinforced composites with reduced manufacturing complexity and cost while maintaining material quality
3Ease of manufacture
If conventional manufacturing processes are used, then carbon fiber structures are produced, but adaptability to diverse shapes and thicknesses is limited
Solution Approach 1:
The invention employs a collapsible mandrel that can dynamically change its diameter during the manufacturing process, allowing the same manufacturing system to produce carbon fiber structures with varying thicknesses and shapes by simply adjusting the mandrel collapse timing, thereby achieving high adaptability while maintaining manufacturing simplicity
4Strength
If thicker fibers are used to achieve structural thickness, then structural integrity is maintained, but ultra-lightweight structures cannot be produced
Solution Approach 1:
The invention changes the fiber thickness parameter by enabling the use of thinner carbon fiber tows (e.g., 3K, 6K, 12K) that would be impossible to process with pultrusion, while maintaining structural integrity through the controlled resin impregnation and curing process that ensures proper fiber bonding and structural properties
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
Enables the production of thin and delicate carbon fiber structures with complex shapes at high speeds and low costs, facilitating innovative applications by creating single, stronger, and lighter structures through continuous manufacturing processes.
Implementation Method 1
a set of outer mold segments may compress the wound carbon fiber threads around the set of inner mold segments by applying heat and pressure to manufacture the carbon fiber structure
Data Source
AI summary
The disclosed technology is generally directed to a method for manufacturing a carbon fiber structure. In one example of the technology, the method may include mounting inner mold segments on a rod. The rod may correspond to one of: a continuous threaded rod and a cogged center rod. A first motor may spin the rod to linearly move the inner mold segments on the rod. While the inner mold segments are moving linearly, a second motor may spin a set of carbon fiber tows mounted on a mandrel around the inner mold segments to wind a set of carbon fiber threads of the set of carbon fiber tows around the inner mold segments. Further, a set of outer mold segments may compress the wound carbon fiber threads around the inner mold segments by applying heat and pressure to manufacture the carbon fiber structure.