Simultaneous Fiber Composite Production with Permeable Separators
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Solution Overview
Problem
Current methods for producing fiber composite components, such as vacuum infusion and water-jet cutting, face challenges including high tool wear, unsatisfactory quality, and high costs, particularly in achieving accurate contour separation and efficient resource utilization.
Innovation Solution
A method involving the simultaneous production of multiple fiber composite components using a semi-finished fibrous pack with permeable planar separation elements, where fibrous materials are layered with matrix material infusion and cutting, allowing for high-quality cutting with reduced air gaps and improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water-jet cutting is used to separate fiber composite components, then cutting quality can be improved, but tool wear increases and costs rise
Solution Approach 1:
The patent combines multiple fiber composite components into a single stacked arrangement and cuts them simultaneously in one operation, merging multiple cutting operations into one. This reduces the cumulative tool wear that would occur from cutting each component separately while maintaining cutting quality through the unified cutting process.
Solution Approach 2:
The patent implements continuous cutting action by cutting through multiple stacked components in a single continuous motion, eliminating the need to retract and reposition the cutting tool between components. This continuous action reduces tool wear by minimizing tool engagement cycles while maintaining consistent cutting quality across all components.
2Productivity
If fiber composite components are produced individually, then production flexibility is maintained, but productivity decreases
Solution Approach 1:
The patent merges multiple individual production operations into a single simultaneous production process by stacking multiple components and cutting them together in one operation. This dramatically increases productivity by producing multiple components in the time it would take to produce one, while the stacking and cutting arrangement remains relatively simple to implement.
3Ease of operation
If air gaps are present between stacked fibrous products, then ease of handling is improved, but cutting precision deteriorates
Solution Approach 1:
The patent introduces separation elements as intermediary components between the stacked fibrous products. These separation elements fill the air gaps to provide mechanical support and maintain precise positioning during cutting, ensuring contour accuracy. At the same time, they allow for easy identification and separation of components after cutting, maintaining handling ease.
4Manufacturing precision
If separation elements are added between fibrous products, then cutting precision is improved, but device complexity increases
Solution Approach 1:
The separation elements serve as simple intermediary components that are easily inserted between stacked fibrous products. They provide the necessary structural support for precise cutting without requiring complex machinery or procedures. The separation elements are basic components that simplify the overall system by providing a straightforward solution to maintain positioning accuracy.
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 method reduces tool wear, enhances cutting quality, and decreases production costs by enabling the simultaneous production of high-quality fiber composite components with improved resource efficiency and accuracy.
Implementation Method 1
the at least one planar separation element at least in portions is permeable to the matrix material
Implementation Method 2
infusing the semi-finished fibrous pack with the matrix material
Implementation Method 3
The German patent and trademark office has identified the following prior art when researching the priority application pertaining to the present application: DE 10 2014 224 720 A1, and Martin Perterer: Schadensidentifikation und -bewertung de CFK-Bauteilen mittels phasenmodulierter Thermographie
Data Source
AI summary
A method for the simultaneous production of two or more fiber composite components, to a fiber composite component, to a rotor blade of a wind power installation, as well as to a wind power installation. A method for the simultaneous production of two or more fiber composite components, in particular of two or more substantially identical fiber composite components which have a component contour, the method comprising providing at least one fibrous material, at least one planar separation element, and at least one matrix material, wherein the at least one planar separation element at least in portions is permeable to the matrix material; producing a semi-finished fibrous pack by disposing the fibrous material layer-by-layer so as to form semi-finished fibrous products stacked on top of one another, wherein at least one of the planar separation elements is in each case disposed between the semi-finish fibrous products; infusing the semi-finished fibrous pack with the matrix material; cutting the component contour into the infused semi-finished fibrous pack.