Corrugated Macroporous Spacer for Composite Shaping
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Solution Overview
Problem
Existing fabric shapers for hardenable materials require numerous spacer threads, leading to stress concentration zones and complexity in manufacturing, and struggle with ensuring even separation of plies for proper material insertion.
Innovation Solution
A shaping structure featuring two sheets with a corrugated macroporous spacer sheet that provides resistance, self-supporting properties, and facilitates even material distribution, eliminating the need for additional reinforcement and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If numerous spacer threads are used to provide sufficient strength and separation, then the resistance to separation forces is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention extracts the spacer function from individual threads and consolidates it into a single continuous spacer element that spans between the plies. This spacer element is formed by extending the leading edge of the leading ply backward, creating a unified structure that provides separation without requiring multiple discrete threads.
Solution Approach 2:
The invention merges the spacer function with the leading ply itself by extending its leading edge backward. This integration eliminates the need for separate spacer components and reduces the overall number of elements in the structure while maintaining the separation function.
2Strength
If numerous spacer threads are used to ensure sufficient strength, then the resistance to separation forces is improved, but the manufacturing complexity increases
Solution Approach 1:
The spacer function is extracted from multiple discrete threads and consolidated into a single continuous element formed by extending the leading ply backward, simplifying the manufacturing process.
Solution Approach 2:
The spacer is merged with the leading ply as a single continuous element, eliminating the need for separate manufacturing and assembly steps for multiple spacer threads.
3Stability of the object's composition
If spacer threads are tensioned to maintain separation, then the separation between plies is ensured, but stress concentration zones are created that may produce tear initiations
Solution Approach 1:
The discrete thread structure is replaced by a continuous spacer element, eliminating the periodic stress concentration zones that occur at thread-seam intersections while maintaining continuous support for ply separation.
Solution Approach 2:
Instead of using discrete tensioned threads that create localized stress points, the invention uses a continuous extended leading edge that distributes stress uniformly along its length, inverting the approach from point-based to line-based support.
4Stability of the object's composition
If two plies are kept separated by spacer threads, then the separation is maintained, but additional components are required that increase device complexity
Solution Approach 1:
The spacer function is merged with the leading ply by extending its leading edge backward, creating a unified structure that eliminates the need for separate spacer components while maintaining effective ply separation.
Solution Approach 2:
The leading edge of the leading ply serves dual functions: it maintains the separation between plies and provides the forward-facing surface of the formed article, eliminating the need for separate spacer components.
5Stability of the object's composition
If two plies are kept separated by spacer threads, then the separation is maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The spacer function is merged with the leading ply as a single continuous element formed by extending the leading edge backward, eliminating the need for separate manufacturing and assembly steps for multiple spacer threads.
Solution Approach 2:
The discrete spacer thread components are extracted and replaced by a single continuous element formed from the leading ply itself, simplifying the manufacturing process.
Data Source
AI summary
This shaping structure (1) comprises two shaping sheets (5, 7) facing each other at a distance from one another. According to the invention, the shaping structure (1) further comprises a macroporous spacer sheet (9), the spacer sheet (9) being arranged between the two shaping sheets (5, 7) and being corrugated in such a way as to form a series of alternating even peaks (18) and odd peaks (20) distributed in a first direction (D1) of the shaping structure, at least one of the even peaks (18) being attached to the first shaping sheet (5), at least one of the odd peaks (20) being attached to the second shaping sheet (7), each peak (18, 20) attached in this way defining an attachment surface (22, 26) for attachment to the shaping sheet (5, 7) to which this peak (18, 20) is attached.