Fabric Wrapping Apparatus with Nonslip Support for Composite Preforms
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Solution Overview
Problem
The challenge in forming fabric preforms for composite components lies in avoiding distortions and imperfections during the wrapping process, which can lead to non-uniformity and compromised mechanical properties in the final composite parts, particularly in applications requiring high strength-to-weight ratios like aircraft components.
Innovation Solution
An apparatus and method involving a support member with a nonslip surface and a primary securing member, such as a vacuum-actuated film, are used to maintain the original configurations of the fabric's outer surfaces by applying pressure and tensioning the axial tows independently, while a secondary securing member increases pressure on the fabric to prevent distortion and ensure uniform wrapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fabric is wrapped around a form to create a fabric preform, then the fabric can be applied to form composite components, but the fabric may become distorted creating wrinkles or waviness that compromise structural integrity
Solution Approach 1:
The patent applies tensioning forces to the fabric during wrapping to counteract distortion. By actively controlling the mechanical parameters (tension, pressure) during the wrapping process, the fabric maintains its intended configuration and prevents wrinkles or waviness that would compromise structural integrity.
Solution Approach 2:
The patent prepares the fabric by tensioning axial tows and positioning support members before the actual wrapping occurs. This preliminary preparation ensures that the fabric is pre-configured to resist distortion during wrapping, preventing defects before they occur rather than correcting them afterward.
2Productivity
If multiple layers of material are wrapped around a form, then composite components can be formed, but unintended areas of bulk develop before resin application resulting in non-uniformity
Solution Approach 1:
The patent uses support members and securing members that apply controlled pressure and tension to the fabric layers during wrapping. By dynamically adjusting these mechanical parameters, the system prevents bulk formation and maintains uniform layer distribution, ensuring consistent fabric preform quality across multiple layers.
Solution Approach 2:
The patent employs a controlled wrapping process where the position and tension of fabric layers are monitored and adjusted during wrapping. This feedback mechanism ensures that each layer is applied uniformly and prevents bulk formation, maintaining precision even as productivity increases through multi-layer wrapping.
3Manufacturing precision
If fabric is tensioned and secured during wrapping, then fabric configuration is maintained preventing distortion, but the device complexity increases with support members and securing mechanisms
Solution Approach 1:
The patent divides the fabric control system into discrete functional elements: support members that engage specific portions of the fabric, securing members that apply localized pressure, and tensioning mechanisms for axial tows. This segmentation allows each component to perform a specific function efficiently, maintaining precision without requiring an overly complex monolithic system.
Solution Approach 2:
The patent introduces support members as intermediary elements between the fabric and the wrapping form. These intermediaries simplify the overall system by providing a straightforward mechanism to maintain fabric configuration without requiring complex direct control of the fabric itself throughout the wrapping process.
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 enhances the quality and consistency of fabric preforms by maintaining the fabric's original configurations, resulting in improved mechanical properties and a higher fabric-to-resin volumetric ratio in the final composite components.
Implementation Method 1
The support member includes a nonslip portion directly engaging a first outer surface of the fabric
Implementation Method 2
a primary securing member engaging and applying pressure on the fabric at a second outer surface of the fabric opposite the first outer surface
Implementation Method 3
a primary securing member, such as a vacuum-actuated film
Data Source
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AI summary
An apparatus (80) for controlling a composite fabric (44) having internal axial tows (46) includes a support member (82) configured to engage the fabric substantially up to a composite component form. The support member includes a nonslip portion (84) directly engaging a first outer surface of the fabric. The apparatus further includes a primary securing member (86, 86', 86'') engaging and applying pressure on the fabric at a second outer surface of the fabric opposite the first outer surface. Upon displacement of the axial tows of the fabric relative to the first and second outer surfaces, the support member and the primary securing member substantially maintain original configurations of the first and second outer surfaces of the fabric engaged between the support member and the primary securing member.