Dynamic N×N Braided Structures for Complex Preform Geometries
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Solution Overview
Problem
Conventional braiding machines struggle with creating braided structures on preforms with complex geometries, particularly those with cross-sectional diameter ratios exceeding 3:1, leading to distortion, bunching, and uneven tension distribution, and lack flexibility in adjusting braid architectures during the braiding process.
Innovation Solution
A braiding machine with a plurality of tow carrier devices that can form N×N braid architectures, allowing for high compaction and longitudinally varying braid structures, using horn disks with radial slots to accommodate varying numbers of tow carrier devices and specialized tow carrier devices to manage tension and prevent 'sawing' effects, enabling the creation of braided products with complex geometries without distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional 2×2 braid architecture is used on preforms with large cross-sectional diameter ratios, then the braiding process can accommodate complex geometries, but distortion and bunching occur in the braided structure
Solution Approach 1:
The patent implements dynamic adjustment of braid architecture along the longitudinal axis of the preform. The braiding machine transitions from conventional static 2×2 braid architecture to dynamic N×N braid architectures where N varies along the length of the preform. This allows the braid structure to adapt to varying cross-sectional diameters, maintaining uniform tension and preventing distortion and bunching in regions with large diameter ratios.
Solution Approach 2:
The patent changes the architectural parameter N of the braid structure along the longitudinal axis. By varying N from section to section, the patent optimizes the braid architecture for different cross-sectional geometries. This parameter change enables the braided structure to maintain uniform tension distribution and eliminate distortion while accommodating complex preform shapes.
2Manufacturing precision
If the number of tow carrier devices is increased to form high compaction braided structures, then uniform tension and reduced distortion are achieved, but device complexity increases
Solution Approach 1:
The patent segments the braiding process into multiple sections along the longitudinal axis of the preform. Each section uses a specific N×N braid architecture with an optimized number of tow carrier devices. This segmentation allows high compaction and uniform tension in critical sections without requiring all sections to use the maximum number of carriers, thereby reducing overall device complexity while maintaining manufacturing precision where needed.
Solution Approach 2:
The patent applies different braid architectures (different N values) to different sections of the preform based on local geometric requirements. Sections with larger cross-sectional diameter ratios use higher N values for high compaction and uniform tension, while sections with smaller ratios use lower N values. This local quality approach achieves uniform tension distribution without unnecessarily increasing device complexity throughout the entire structure.
3Ease of manufacture
If conventional braiding machines are used, then simple 2×2 braid structures are produced, but flexibility in adjusting braid architecture during braiding is limited
Solution Approach 1:
The patent transforms the static braiding system into a dynamic one by enabling real-time adjustment of the braid architecture parameter N during the braiding process. The braiding machine can transition between different N×N architectures along the longitudinal axis, providing flexibility to adapt to varying preform geometries while maintaining ease of manufacture through automated control of the dynamic architecture changes.
Data Source
AI summary
A braided sleeve with complex geometry, including changes to the geometry along the braided sleeve's longitudinal axis are described. In particular, along a first portion of the braided sleeve's longitudinal axis, multiple tows are intertwined with each other. Along a second portion, one of tows is removed from being intertwined with the other tows and is relocated to an interior or an exterior of the braided sleeve. A third portion includes the removed tow being intertwined with the plurality of tows again. In this manner, the braided sleeve may provide coverage of preforms with varying diameters along the longitudinal axis of the preforms.