Curved Reinforcing Fiber Substrate for Wrinkle-Free Preform Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing curved fiber-reinforced resin composite materials with a longitudinal curved shape are inefficient due to lengthy processes, require specialized devices, and often result in waviness or wrinkles, especially when forming preforms with complex cross-sectional shapes like Z-shaped sections.
Innovation Solution
A process involving a curved reinforcing fiber substrate with reinforcing fiber yarns oriented along the circumferential direction and auxiliary weft yarns crossing them, allowing for efficient layering and formation of flat-plate like reinforcing fiber layers, which are then layered and bonded using a resin material to maintain the desired shape and orientation, enabling the production of preforms with complex cross-sectional shapes without wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to produce curved fiber-reinforced resin composite materials, then the desired curved shape can be achieved, but the production time is excessively long and specialized devices are required
Solution Approach 1:
The curved reinforcing fiber substrate is divided into multiple flat-plate like reinforcing fiber layers, each having a curved shape as a planar shape. This segmentation allows each layer to be prepared independently using simple devices, then assembled together to form the complete curved structure, eliminating the need for complex specialized forming devices while reducing production time
Solution Approach 2:
The reinforcing fiber layers are prepared in advance with their curved shapes and fiber orientations predetermined before final assembly. The flat-plate like layers are manufactured separately with precise fiber alignment, then bonded together to form the final curved composite structure, allowing parallel processing and reducing overall production time
2Manufacturing precision
If multiple flat-plate like reinforcing fiber layers are layered to form curved shapes, then the fiber orientation can be maintained, but waviness and wrinkles occur in the formed preform
Solution Approach 1:
Each reinforcing fiber layer is designed as a thin flat-plate like structure with curved shape, allowing it to flex and conform to the desired three-dimensional preform geometry without creating surface defects. The thin film nature of each layer enables smooth integration while maintaining fiber orientation, preventing waviness and wrinkles in the final assembled preform
Solution Approach 2:
The solution transitions from attempting to form a single complex 3D curved substrate to assembling multiple 2D flat-plate like layers with curved shapes. By working in the planar dimension first and then assembling in the third dimension, the method maintains fiber orientation precision while achieving smooth complex 3D shapes without surface defects
3Adaptability or versatility
If complex cross-sectional shapes like Z-shaped sections are formed, then the structural requirements are met, but the process becomes extremely complex and time-consuming
Solution Approach 1:
The complex cross-sectional shape is achieved by assembling multiple flat-plate like reinforcing fiber layers, each contributing a portion of the final geometry. This segmentation allows independent preparation of each layer with simple devices, then assembly to form complex cross-sections like Z-shaped sections, maintaining high adaptability while improving production efficiency
Solution Approach 2:
Each layer is prepared in advance with its specific curved shape and fiber orientation predetermined, allowing complex cross-sectional geometries to be achieved through assembly of pre-formed layers rather than complex forming operations, significantly improving productivity
Data Source
Figure 1
Figure 2(A)~2(C)
Figure 3(A)~3(C)
AI summary
Provided are: a curved reinforcing fiber substrate (1) characterized by having a curved planar shape and by comprising reinforcing fiber yarns (2) arranged parallel with a direction along a circumferential direction (3) of the curved shape and auxiliary weft yarns (4) arranged in directions crossing a plurality of the reinforcing fiber yarns (2) each arranged in one direction of the circumferential direction (3); a curved reinforcing-fiber layered product using the substrate; a preform; a reinforced composite material; and processes for producing those. These can be provided as: a reinforcing fiber substrate curved along the longitudinal direction and arranged with reinforcing fibers along the curved shape in a desirable formation; a curved reinforcing-fiber layered product layered with at least one layer of the reinforcing fiber substrate and a process for producing the layered product efficiently in a short time; a preform using the layered product and a process for forming the preform efficiently; and a long-extended curved fiber-reinforced composite material and a process for producing the same.