Curved Object Manufacturing Using Tensile Stress Drawing
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Solution Overview
Problem
Existing processes for manufacturing curved objects from stacked polymeric fibre plies often result in wrinkling due to reliance on deformability and controlled material addition, which is complex and time-consuming, and limited by shear and slip mechanisms.
Innovation Solution
Applying a tensile stress to the fibres at a temperature between their melting point and 20°C below it, allowing the fibres to be drawn and change length, thereby reducing wrinkling and enabling the production of wrinkle-free objects with homogeneous properties without relying on deformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If controlled material addition and shear/slip mechanisms are used to form curved objects from fibre plies, then the object can be formed, but wrinkling occurs in the material
Solution Approach 1:
The patent applies tensile stress to the fibres at elevated temperature (between the melting point and 20°C below it) to enable fibre drawing and length change. This parameter change in temperature and stress state allows the fibres to deform without wrinkling, resolving the contradiction between forming curved shapes and maintaining surface quality
Solution Approach 2:
The patent replaces the traditional blankholder clamping mechanism with a tensile stress application system. Instead of relying on shear and slip between plies under compression, the invention uses tensile loading to draw fibres and achieve shape change, eliminating the wrinkling problem associated with the mechanical clamping approach
2Shape
If a blankholder is used to clamp fibre plies in a controlled manner, then material can be drawn into the die, but the process becomes complex and time-consuming
Solution Approach 1:
The patent removes the complex blankholder clamping mechanism from the forming process. By extracting this complicated device and replacing it with a simple tensile stress application system, the invention achieves material distribution through fibre drawing without the complexity and time consumption of controlled clamping
Solution Approach 2:
The fibre plies themselves perform the material distribution function through fibre drawing under tensile stress. Instead of requiring an external blankholder to control material flow, the fibres self-organize and distribute material as they are drawn into the curved shape, simplifying the overall process
3Stability of the object's composition
If fibre plies with low internal and mutual deformability are used, then material stability is maintained, but wrinkling still occurs in drawn material
Solution Approach 1:
The patent changes the temperature parameter to enable fibre drawing at elevated temperature (between melting point and 20°C below it). This temperature increase allows fibres in stable plies to be drawn and lengthened without causing wrinkling, maintaining both material stability and surface quality
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 process allows for the production of curved objects with improved mechanical and ballistic properties, reduced wrinkling, and more homogeneous fibre orientation, enhancing the quality and homogeneity of the final product.
Implementation Method 1
imposing a tensile stress on the fibres, at a temperature lying between the melting point of the fibres at the imposed tensile stress and 20° C. below said melting point, which tensile stress is high enough for the fibres to be drawn
Data Source
AI summary
The invention relates to a process for the manufacture of an object, curved in one or more directions, from a package of at least one stacked ply containing polymeric fibers by the deforming thereof at elevated temperature, the process comprising imposing on the fibres a tensile stress at a temperature lying between the melting point of the fibers at the imposed tensile stress and 20° C. below the melting point, which tensile stress is high enough for the fibers to be drawn. This process allows objects, curved in one or more directions, to be produced from flat fiber plies without appreciable wrinkling using even fiber plies with low internal and/or mutual deformability and without material being drawn into the die in a controlled manner. The invention also relates to an object, curved in one or more directions, obtainable by the process according to the invention.