Fiber Application Head with Anti-Adherent Sheath Roller
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Solution Overview
Problem
Existing fiber placement machines face challenges in using a wide variety of resins, particularly thermoplastic resins, due to complex and deteriorating compacting rollers and heating systems, which lead to issues like sheath degradation and combustion fumes deposition, limiting the operational flexibility and efficiency.
Innovation Solution
A fiber application head with a compacting roller featuring a rigid central tube and a flexible, elastically deformable cylindrical part covered by an anti-adherent sheath with lateral portions for translational and rotational blocking, combined with a heating system and an air knife blowing system to manage high temperatures and combustion fumes effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metallic compacting roller is used for high temperature applications, then heat resistance is improved, but device complexity and cost increase due to required cooling systems
Solution Approach 1:
The patent uses a flexible roller covered with a heat-resistant film (such as PTFE or other high-temperature resistant coatings) instead of a metallic roller with cooling systems. The film allows the roller to operate at high temperatures (up to 400°C) while maintaining simplicity, as the flexible material itself provides the necessary thermal management without requiring active cooling circuits.
2Adaptability or versatility
If a segmented metallic compacting roller is used to adapt to profile, then adaptability is improved, but device complexity increases due to multiple independently mounted segments
Solution Approach 1:
The patent employs a single flexible roller that can dynamically adapt to the mold profile through the elastic deformation of the flexible material itself. The flexibility of the roller cover allows it to conform to complex surfaces without requiring multiple rigid segments, thereby achieving profile adaptation while maintaining structural simplicity.
3Temperature
If high heating temperatures are used for thermoplastic resins, then resin melting and adhesion are improved, but sheath degradation and combustion fumes increase
Solution Approach 1:
The patent uses heat-resistant coating materials (such as PTFE, PFA, or other high-temperature stable polymers) that can withstand temperatures up to 400°C without degrading. These materials maintain their mechanical and chemical properties at high temperatures, preventing sheath degradation and reducing combustion fumes while still allowing the underlying resin to melt and adhere properly.
Solution Approach 2:
The flexible roller with heat-resistant coating is designed as a consumable component that can be easily replaced when worn or contaminated. This approach is more economical than maintaining complex cooling systems or segmented metallic rollers, and the simple replacement process minimizes downtime while ensuring continuous operation at high temperatures.
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
The solution enables the use of various thermosetting and thermoplastic resins with uniform compaction, maintaining roller stability above 400°C, preventing sheath deterioration, and effectively managing combustion fumes, thus enhancing the production of composite material parts with improved fiber layup quality and operational safety.
Implementation Method 1
a heating system capable of emitting thermal radiation in the direction of the fiber or fibers in the direction of the band
Implementation Method 2
an anti-adherent sheath covering the cylindrical part
Implementation Method 3
at least one cylindrical part made of a flexible material, elastically deformable, assembled coaxially, directly or indirectly, on the central tube
Data Source
AI summary
A fiber application head for producing composite material parts, comprising a compacting system comprising a compacting roller comprising a rigid central tube and at least one cylindrical part made of a flexible material and assembled on said central tube, and an anti-adherent sheath covering the cylindrical part, and a heating system that is able to emit thermal radiation in the direction of the (s). The anti-adherent sheath has lateral portions extending beyond the cylindrical surface of the cylindrical part in the direction of the rotation axis of the roller, the assembly of the anti-adherent sheath to said cylindrical part being carried out by the lateral portions.