Double-Diaphragm Forming for Precise Fibre Preform Placement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing diaphragm forming methods struggle to achieve precise control over the positional relationship between diaphragms and mould tools, especially for high-performance composite components requiring specific material placement and orientation, leading to difficulties in forming complex shapes with varied materials.
Innovation Solution
A method involving a double diaphragm forming process where one diaphragm is offset from the forming surface, allowing for mechanical displacement relative to the former, combined with vacuum manipulation, to achieve precise conformity with the mould surface, and the use of heat-activatable binders to set the preform in shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a vacuum is drawn between the diaphragm and the mould tool to pull the diaphragm into contact with the mould, then the blank is held in close conformity with the shape of the mould tool, but precise control over the positional relationship between the diaphragms and the mould tool is difficult to achieve
Solution Approach 1:
The diaphragm is mechanically displaced to a predetermined position before the vacuum is drawn. This preliminary mechanical positioning ensures that the diaphragm starts from a known, controlled location, and the subsequent vacuum action maintains this precise positional relationship while achieving conformity with the mould surface.
2Adaptability or versatility
If the diaphragms are elastic to allow flexibility in the forming process, then the blank can be shaped, but precise control over the positional relationship between the diaphragms and the mould tool is difficult to achieve
Solution Approach 1:
The diaphragm system transitions from a static elastic membrane to a dynamically controlled system where mechanical displacement is used to establish precise initial positions. The diaphragm remains elastic for flexibility during forming, but its position is actively controlled through mechanical means before vacuum application, resolving the contradiction between flexibility and precision.
3Reliability
If varied materials are combined to create high performance parts with specific materials at particular points, then the component performance is improved, but the complexity of positioning and orienting these materials increases
Solution Approach 1:
The fibre preform is mechanically displaced to a predetermined position before the vacuum is drawn. This preliminary positioning allows complex multi-material configurations to be pre-established with precise orientation and location, and the subsequent vacuum action maintains this arrangement while achieving conformity with the mould surface, thereby reducing the complexity of positioning varied materials.
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 precise shaping of complex composite components by ensuring accurate material placement and orientation, improving the conformity of fibre articles to mould surfaces, and enhancing the efficiency of the forming process.
Implementation Method 1
Then a vacuum is drawn between the diaphragm and the mould tool. This pulls the diaphragm into contact with the mould, and eventually causes the blank to be held in close conformity with the shape of the mould tool.
Implementation Method 2
Then the blank can be set in shape, for example by applying heat to the mould tool so as to cure a resin that is infused into the blank.
Data Source
AI summary
A method of forming a fibre article, comprising: providing a former having a contoured forming surface; locating a fibre preform between a first diaphragm and a second diaphragm, the second diaphragm being offset from the forming surface; drawing a vacuum between the first and second diaphragms so as to hold the preform captive between the diaphragms; displacing the diaphragms relative to the former so as to bring a part of the second diaphragm adjoining the preform into partial conformity with the former; drawing a vacuum between the second diaphragm and the former so as to increase the conformity between the said part of the second diaphragm and the former; and setting the preform in its configuration