Device and method for producing a molded body from a fiber material
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Solution Overview
Problem
The production of fiber-reinforced structural components with complex geometries from three-dimensional woven structures is challenging due to the need for manual operations, high costs, and difficulties in preventing wrinkles, especially in aerospace and automotive applications where high-quality components with specific mechanical properties are required.
Innovation Solution
A method and device for producing molded bodies from fiber materials involve iterative activation of a binder material within a textile structure, allowing for progressive shaping and fixing of the structure area-by-area, using manipulators and electromagnetic radiation or electric current to prevent wrinkling and internal stresses, enabling continuous production of complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If three-dimensional woven structures are used to produce fiber-reinforced structural components with complex geometries, then the mechanical properties and functional characteristics are improved, but the production process becomes difficult, costly, and time-consuming due to manual operations
Solution Approach 1:
The patent divides the three-dimensional woven structure into multiple two-dimensional layers that are produced separately by standard weaving machines. These layers are then assembled iteratively to form the complete complex geometry, replacing manual operations with automated layer-by-layer construction
Solution Approach 2:
The binder material is activated in advance during the assembly process to fix individual layers before subsequent layers are added. This preliminary fixation enables automated handling and positioning of layers without requiring manual operations during final assembly
2Manufacturing precision
If iterative activation of binder material is used to fix textile structure area-by-area, then the formation of wrinkles and internal stresses is prevented, but the process complexity increases
Solution Approach 1:
The binder activation process is segmented into iterative steps corresponding to each layer assembly. Only the binder material in the current layer being assembled is activated, rather than activating the entire structure at once. This localized, sequential activation prevents wrinkles and internal stresses while maintaining manageable process complexity through automation
Solution Approach 2:
The binder activation occurs continuously during the assembly process as each layer is positioned and fixed before the next layer is added. This continuous iterative activation ensures consistent quality throughout the structure without requiring separate complex post-processing steps
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 simplifies the production of high-quality, complex fiber composite components by automating the shaping and fixing process, reducing costs and time, and allowing for the creation of components with varied geometries and anisotropic tensile strengths.
Implementation Method 1
the binder material is activated by the action of heat in the preform mold
Implementation Method 2
electric current to prevent wrinkling and internal stresses
Data Source
AI summary
The invention relates to a method (30) for producing a molded body (52) from a fiber material (50), wherein a textile structure (54) that is provided with a binder material is first produced from the fiber material (50) using a textile technology (step 32). This textile structure (54) is subsequently shaped (step 34) and fixed in a predetermined three-dimensional form by an activation of the binder material (step 36). The activation of the binder material (step 36) is carried out iteratively here. This means that the binder material is activated progressively in some selected areas of the textile structure (54) (and the shape of the structure is fixed in these areas as a result) before an activation/fixing is carried out in other areas of the textile structure (54).