Fiber Application Machine Tension Control
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Solution Overview
Problem
Current fiber application machines are cumbersome, expensive, and inefficient due to complex conveying and guiding systems, limited space requirements, and the need for intermediate compaction operations and polymerization in an autoclave, which restricts speed and increases costs.
Innovation Solution
A fiber application machine with a tension limiting system using parallel cylinders and flexible conveying tubes, allowing for constant fiber tension and reduced space requirements, along with on-line resin impregnation capabilities, enabling high-speed fiber placement without the need for motor-driven slack recovery systems and autoclave polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If motor-driven unwinding systems with automatic control are used for each bobbin, then fiber tension can be limited and placed flat on concave surfaces, but the machine becomes cumbersome, expensive, and space-consuming with restricted unwinding speed
Solution Approach 1:
The patent merges multiple independent bobbin unwinding systems into a single creel structure where multiple bobbins are mounted on a common support. The bobbins unwind freely without individual motor-driven systems, eliminating complex automatic control mechanisms while maintaining fiber placement quality through the tension limiting system's friction-based tension control.
Solution Approach 2:
The patent extracts and removes the motor-driven unwinding systems and automatic control mechanisms from each bobbin position. Instead, bobbins are mounted to rotate freely on the creel, eliminating the need for complex drive systems while the tension limiting system provides sufficient tension control for proper fiber placement.
2Ease of operation
If complex conveying and guiding systems are used to handle pre-impregnated fibers, then fiber placement can be achieved, but the systems get clogged, are cumbersome, and restrict placement speed
Solution Approach 1:
The patent changes the physical state and properties of fibers by using dry fibers instead of pre-impregnated fibers. This eliminates the adhesive resin that causes clogging in conveying systems. The fibers are impregnated with resin only at the moment of application to the mold, allowing high-speed placement without clogging issues.
Solution Approach 2:
The patent performs resin impregnation at the last moment - just before fiber application to the mold - rather than pre-impregnating fibers before storage and conveyance. This preliminary action at the application point eliminates clogging problems during conveying while ensuring proper fiber impregnation for composite part manufacturing.
3Ease of manufacture
If pre-impregnated fibers are stored at ambient temperature, then storage is simple, but fibers have limited lifespan and must be stored at low temperatures
Solution Approach 1:
The patent changes the storage conditions parameter by storing fibers as dry fibers at ambient temperature rather than pre-impregnated fibers at low temperatures. This parameter change extends fiber shelf life indefinitely while maintaining ease of storage, as dry fibers do not suffer from resin degradation or adhesion issues at room temperature.
4Manufacturing precision
If intermediate compaction operations are performed to discharge trapped air, then fiber deposition quality improves, but lead time is extended and machine design becomes more complex
Solution Approach 1:
The patent eliminates the need for separate intermediate compaction operations by ensuring continuous, smooth fiber application directly onto the mold. The tension limiting system and simplified conveying mechanism deliver fibers continuously without folds or air traps, removing the need for additional compaction steps and extending production lead time.
5Manufacturing precision
If autoclave polymerization is used to guarantee low porosity, then composite quality improves, but implementation costs considerably increase
Solution Approach 1:
The patent changes the manufacturing process parameters by using dry fiber application with resin impregnation at the application point, followed by vacuum infusion or RTM processes. This alternative parameter approach achieves low porosity composite parts without requiring expensive autoclave polymerization, significantly reducing implementation costs while maintaining composite quality.
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 machine achieves high-speed fiber placement with reduced space and cost, eliminating the need for autoclave polymerization and motor-driven unwinding systems, while maintaining fiber quality and reducing porosity in composite parts.
Implementation Method 1
The cylinders are rotated by a drive means, automatically controlled by a control unit of the machine, so that the peripheral speeds of the cylinders are higher than the moving speed of the fibers at the application roller, in order to exert a tensile stress on the fibers coming from the storing means
Data Source
AI summary
A fiber application machine including a fiber application head with an application roller for the production of parts made of composite materials. The fiber application head further includes a guiding system to guide the fibers onto the application roller and/or means for the application of resin to each fiber as the fibers leave the guiding system. The fiber application machine can also include a fiber storing system and conveying means for conveying the fibers from the fiber storing system to the application head. The conveying means can comprise flexible tubes, each tube being able to receive a fiber in its inner channel. The conveying means can further include a tension limiting system positioned between the application head and the storing system. The fiber application machine can further include a system for moving the application head.