Deformable Guide Roller for Dynamic Fiber Bundle Spreading
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices struggle to lay continuous fiber bundles consistently on frames or curved surfaces, leading to overlaps, gaps, deflections, and entanglements, which can reduce the strength of fiber composite materials and result in residual stresses and component failure.
Innovation Solution
A device with a deformable guide roller that modifies tensile stress by changing the guide path of the continuous fiber bundle, allowing for dynamic adaptation of the bundle width to match local geometric characteristics, using mechanisms like axial compression, radial deformation, or fluid-based swelling cushions to optimize fiber distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a continuous fiber bundle is laid on a curved surface with fixed bundle width, then the laying process is simple, but overlaps and gaps occur leading to inconsistent fiber distribution
Solution Approach 1:
The patent applies the dynamics principle by making the fiber bundle width dynamic rather than fixed. A spreading device with adjustable spreading edges is introduced that can modify the bundle width in real-time during the laying process. This allows the bundle width to adapt to the local curvature of the workpiece surface, ensuring consistent fiber distribution without overlaps or gaps while maintaining a relatively simple overall device structure.
Solution Approach 2:
The patent implements parameter changes by varying the bundle width parameter according to the workpiece geometry. The spreading device enables continuous adjustment of the bundle width parameter to match the local surface characteristics, transforming a static laying process into a dynamic one that maintains optimal fiber distribution across surfaces with varying curvature.
2Productivity
If the fiber bundle width is increased to cover larger areas, then productivity improves, but the thickness increases making matrix penetration difficult
Solution Approach 1:
The patent resolves this contradiction by introducing a dynamic spreading mechanism that can adjust the bundle width during the laying process. This allows the system to optimize between productivity and quality by varying the bundle width according to the specific requirements of each workpiece section, enabling both high-speed laying and good matrix penetration where needed.
Solution Approach 2:
The patent applies local quality by allowing different sections of the fiber bundle to have different widths tailored to the local workpiece characteristics. The spreading device can create variable bundle widths along the bundle length, providing narrower sections where matrix penetration is critical and wider sections where productivity is prioritized, thus achieving both goals simultaneously.
3Reliability
If conservative bundle design is used to avoid strength loss, then reliability improves, but component weight increases
Solution Approach 1:
The patent uses parameter changes to optimize the bundle width dynamically during laying. By adjusting the bundle width parameter to match the local curvature and surface area of the workpiece, the system achieves more accurate fiber placement with less material waste. This eliminates the need for conservative over-design, maintaining fiber bundle strength while reducing unnecessary weight from excess material.
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
This approach ensures uniform fiber distribution, reduces material weight, minimizes defects, and enhances mechanical properties by adapting the bundle width to the product geometry, thereby improving the quality and reliability of fiber composite materials.
Implementation Method 1
at least one means for modifying a force acting on the continuous fiber bundle comprises at least one swelling cushion (25) for modifying a guide path of the continuous fiber bundle (30, 40) by radially expanding a guide roller (20)
Implementation Method 2
the swelling cushion (25) for modifying a guide path of the continuous fiber bundle (30, 40) by radially expanding a guide roller (20)
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
Production of a fiber-containing product and unwinding of a continuous fiber bundle (30, 40, 50) from a material spool (110), guiding the continuous fiber bundle around at least one rotating guide roller (10, 20, 120, 130), laying the continuous fiber bundle in a first bundle width (b1), modifying a tensile stress acting on the continuous fiber bundle (30, 40, 50) and laying the continuous fiber bundle in a second bundle width (b2) different from the first; the modification includes changing a guide path of at least a part of the continuous fiber bundle (30, 40, 50). Device for producing a fiber-containing product comprising a guide roller with a rotational axis (11, 21) and a deformable outer layer (12, 22).