Fiber Application Head Compacting Roller for Convex Surfaces
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Solution Overview
Problem
Current fiber application machines are unable to effectively apply strips of fibers to convex surfaces or edges with small radii of curvature, leading to air bubble retention and subsequent material folds, which compromises the mechanical properties of final parts, particularly in applications like aircraft wing spars and wind turbine blades.
Innovation Solution
A method and machine design that incorporates a compacting system with a compacting roller and an additional downstream compacting member, allowing for continuous contact and pivoting around edges or convex surfaces without slippage, ensuring thorough compaction and air evacuation during the fiber application process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single compacting roller is used to apply fibers to convex surfaces or edges, then the application process is simple, but air bubbles are retained and material folds form, compromising mechanical properties
Solution Approach 1:
The compacting system is divided into two distinct elements: a first compacting element (roller) that applies the fiber strip to the mold, and a second compacting element (plate or roller) that compacts the strip after application. This segmentation allows each element to perform its specific function optimally, with the second element specifically addressing air bubble removal and fold prevention on convex surfaces and edges.
Solution Approach 2:
The second compacting element performs compaction action preliminarily during the fiber application process, before the resin hardens. This preliminary compaction ensures complete evacuation of air bubbles and proper fiber consolidation while the material is still pliable, preventing defects that would compromise mechanical properties after hardening.
2Area of stationary object
If fibers are applied to edges or convex surfaces with small radius of curvature, then coverage is achieved, but complete compaction is impossible without slippage, leading to air bubble retention
Solution Approach 1:
The second compacting element acts as an intermediary between the fiber strip and the mold surface, providing additional compaction force directly on the applied fibers. This intermediary action ensures complete compaction even on difficult geometries like edges and convex surfaces with small radii of curvature, where the primary roller cannot maintain adequate contact pressure without slippage.
3Shape
If folding and bending operations are performed on flat parts before hardening, then parts with edges and convex surfaces can be produced, but creases form in inner layers, affecting strength properties
Solution Approach 1:
Instead of applying fibers to flat surfaces and then folding/bending the parts to create edges and convex surfaces (the conventional approach), the invention inverts the process by directly applying and compacting fibers onto the final three-dimensional geometry including edges and convex surfaces. This eliminates the need for post-application folding operations that create creases and strength-critical defects in inner layers.
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 the production of parts with edges and convex surfaces that have improved mechanical properties by ensuring complete fiber compaction and air evacuation, eliminating material folds and enhancing the strength of the final product.
Implementation Method 1
the latter maintains continuous pressure on the application surface of the mold to gradually evacuate the air trapped between the strips of fibers deposited
Implementation Method 2
Document JP2005329593 describes an application machine in which the compaction unit comprises a heated compaction roller
Implementation Method 3
the evacuation of the air bubbles is carried out only during the hardening under vacuum
Data Source
Figure 1~2
Figure 3~4C
Figure 4D~4G
AI summary
The present invention relates to a fibre-application method and a machine intended for the production of parts made from composite material, in particular for applying a fiber web onto convex and/or ridged surfaces. The machine includes a fiber application head and a system (5) for moving said application head. The application head includes a compacting system comprising a compacting roller (2) intended to come into contact with the application surface (90) so as to apply the web and a compacting member (3, 103, 203) placed downstream from said compacting roller and having a substantially planar contact surface (32), whereby the contact surface of the compacting member can be applied against an application surface over substantially the entire width of a web along at least one contact line.