Dry Fiber Binding with Heat-Activated Binder and Vacuum Suction
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Solution Overview
Problem
The manual and time-consuming process of connecting dry gussets to dry fiber strands in the manufacturing of fiber-reinforced plastic components, particularly in aeronautics, is inefficient and costly, with the need to untwist and manually position the gussets, which prolongs production times.
Innovation Solution
A continuous, automated process where the dry fiber sliver and strand are unwound and positioned parallel to each other on a conveyor belt, with a heat-activated binder and airtight film ensuring secure fixation and connection without untwisting, using a combination of heat supply and vacuum suction for adhesive activation and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual untwisting and positioning of the gusset is performed, then the gusset can be properly positioned on the base layer, but the production time increases significantly
Solution Approach 1:
The gusset is supplied in a pre-untwisted state from the roll, eliminating the need for manual untwisting during processing. This preliminary preparation resolves the contradiction by maintaining positioning accuracy while dramatically reducing production time.
Solution Approach 2:
The manual mechanical process of untwisting and positioning is replaced by a automated system where the gusset is fed continuously from the roll through guide elements that maintain proper positioning automatically, substituting human labor with a mechanical feed system.
2Productivity
If continuous automated processing is implemented, then production efficiency increases, but the complexity of the processing system increases
Solution Approach 1:
The continuous processing system is divided into distinct functional zones: unwinding zone, positioning zone with guide elements, heating zone with infrared radiation, and cooling zone. Each zone performs a specific function, making the overall complex system manageable and maintainable while achieving high productivity.
Solution Approach 2:
The processing line is designed to handle different fiber materials (carbon fiber, glass fiber, aramid fiber) and different gusset configurations using the same basic equipment, making the system universally applicable to various composite manufacturing tasks.
3Ease of manufacture
If the gusset is supplied twisted from the roll, then storage and handling are simplified, but additional untwisting steps are required
Solution Approach 1:
The gusset is pre-untwisted during the winding process onto the roll, so that when it is fed through the processing line, it is already in the correct state for bonding. This preliminary action eliminates the need for separate untwisting steps.
Solution Approach 2:
Instead of untwisting the gusset before winding it onto the roll, the gusset is wound in such a way that it comes off the roll in the desired untwisted state. This inverts the traditional approach and eliminates the problematic step.
4Strength
If heat-activated binder is used to connect the gusset and base layer, then strong bonding is achieved, but energy consumption increases
Solution Approach 1:
Infrared radiation is used to heat the binder, providing rapid and localized energy delivery that melts the thermoplastic binder quickly and efficiently. This method achieves strong bonding with lower overall energy consumption compared to conventional heating methods.
Solution Approach 2:
The binder is designed as a thermoplastic material that changes its properties at a specific temperature threshold, transitioning from a solid state to a molten state that allows bonding, then solidifying to create the strong bond. This parameter-based approach optimizes energy usage by heating only to the necessary transition temperature.
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 method significantly reduces production time, enhances reproducibility, and optimizes positioning tolerances, allowing for faster and more cost-effective manufacturing while minimizing material distortion and wear, enabling efficient and precise connection of fiber composite components.
Implementation Method 1
The binder is activated by supplying heat, in this case by means of infrared radiation
Implementation Method 2
The fiber strand can be fixed on the conveyor belt by suction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The method involves unwinding a fiber strip (1) and a fiber strand (2) from respective supply rolls (10, 20), and fixing the strip on a conveyor belt (5) using a suction box (9). A flat mantle surface of the strand is positioned on the strip during the unwinding process. The fiber strip and fiber strand are covered using an air-impermeable film i.e. endless film, in a suction area. Heat is supplied during the unwinding process using hot air blowers (7) to cause activation of a binding agent e.g. thin thermoplastic binder nonwoven, and gluing of the fiber strip and fiber strand.