Continuous Fibre-Reinforced Components Using Tubular Cavity Pulling
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Solution Overview
Problem
Existing manufacturing processes for fiber-reinforced composite components face challenges in achieving high fiber orientation, leading to complex and slow production, particularly when dealing with diverse geometries such as branches, junctions, and intersections.
Innovation Solution
A method involving a component body with tubular cavities, using a pulling device to introduce fiber bundles and resin, allowing for the formation of complex geometries by pulling fiber bundles into these cavities, followed by curing the resin and selectively removing soluble polymer material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used to achieve high fiber orientation, then manufacturing precision is improved, but device complexity increases and productivity decreases
Solution Approach 1:
The patent replaces traditional mechanical fiber placement methods with a chemical bonding approach. Fibers are embedded in liquid resin and cured in place, eliminating the need for complex mechanical fiber positioning equipment while achieving high fiber orientation precision through the resin's ability to hold fibers in the desired configuration during curing.
Solution Approach 2:
The patent changes the state of the resin from liquid to solid through curing to achieve fiber fixation. The liquid resin allows fibers to be positioned and oriented freely before curing, and the phase change to solid resin locks the fibers in the desired orientation, enabling high precision without complex mechanical positioning systems.
2Manufacturing precision
If traditional manufacturing processes are used to achieve high fiber orientation, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical fiber placement and positioning systems with a simplified chemical bonding process. Fibers are embedded in liquid resin and cured in place, eliminating the need for sophisticated mechanical equipment while achieving high fiber orientation precision through the resin's ability to hold fibers in the desired configuration.
Solution Approach 2:
The liquid resin acts as an intermediary medium that facilitates fiber positioning and orientation. The resin allows fibers to be easily positioned and oriented before curing, and then locks them in place, serving as a mediator that simplifies the manufacturing process while achieving high precision fiber orientation.
3Manufacturing precision
If complex geometries with branches, junctions, and intersections are manufactured using traditional methods, then manufacturing precision is maintained, but productivity decreases and device complexity increases
Solution Approach 1:
The patent utilizes the phase change of resin from liquid to solid to enable efficient manufacturing of complex geometries. In the liquid state, the resin can be easily injected into complex cavities with branches, junctions, and intersections, allowing fibers to be positioned throughout the complex geometry. Upon curing, the resin solidifies and locks fibers in place, achieving high precision without time-consuming mechanical processes.
Solution Approach 2:
The patent replaces time-consuming mechanical fiber placement methods with a chemical bonding approach suitable for complex geometries. Fibers are embedded in liquid resin that can flow into complex cavities, and the subsequent curing process locks fibers in the desired orientation, dramatically reducing manufacturing time for complex geometries while maintaining high precision.
4Manufacturing precision
If complex geometries with branches, junctions, and intersections are manufactured using traditional methods, then manufacturing precision is maintained, but device complexity increases
Solution Approach 1:
The liquid resin serves as an intermediary that simplifies the manufacturing of complex geometries. It can be easily injected into cavities with branches, junctions, and intersections, carrying fibers to their final positions. The resin then cures and locks fibers in place, eliminating the need for complex mechanical positioning systems while achieving high precision fiber orientation in complex geometries.
Solution Approach 2:
The patent utilizes the phase change of resin from liquid to solid to simplify manufacturing of complex geometries. In the liquid state, the resin flows easily into complex cavities, allowing simple injection processes. Upon curing, the resin solidifies and locks fibers in the desired orientation, achieving high precision without complex manufacturing processes.
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 fiber-reinforced components with improved fiber orientation in diverse geometries, reducing manufacturing complexity and time, and facilitating the production of previously difficult or impossible configurations.
Implementation Method 1
the pulling device has at least one pulling means configured to pull the fiber bundles and transmit compressive force
Implementation Method 2
The resin is then cured until solidification occurs
Data Source
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AI summary
In order to improve manufacturing processes for fiber-reinforced polymer or metal hybrid composite components (26) with regard to their application diversity and preferably to enable the introduction of fiber bundles into a larger number of geometries, such as branches (20), junctions (22), and intersections (24), a manufacturing method for producing a component (26) from a composite material with fiber reinforcement formed from fiber bundles (27) and resin (32) is proposed. First, a component body (10) with a plurality of tubular cavities (16) is provided. Curable resin (32) is introduced into the cavities. Furthermore, a pulling device (28) for the fiber bundles (27) is inserted into at least one of the cavities (16). The pulling device (28) comprises at least one pulling means (30) suitable for pulling the fiber bundles (27) and transmitting compressive force. By pulling the traction device (30), the fiber bundles (27) are drawn into the cavities (16).