Fiber Application Head With Transverse Layup for Complex Composite Shapes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional automated fiber placement methods face challenges in manufacturing large aeronautical composite parts, such as pusher propellers with tulip bases, due to machine head clearance issues at the neck area, and modifying the part shape is not satisfactory.
Innovation Solution
An application head with an applicator roller that applies fibers transversely to its axis, using a fiber strip with predefined orientation, and a pre-applicator roller for initial band application, allowing for varied reinforcement orientations without head contact and enabling simultaneous deposition of multiple layers without creases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional automated fiber placement methods are used to manufacture large aeronautical composite parts with complex geometries like tulip bases, then the machine head clearance at the neck area is insufficient, but modifying the part shape is not satisfactory as the part is designed for a specific function
Solution Approach 1:
The patent inverts the conventional fiber placement approach by depositing fibers transversely to the roller movement direction rather than parallel to it. This allows the applicator roller to move around complex geometries like tulip bases without the head contacting the neck area, as the fiber deposition orientation is perpendicular to the traditional direction, enabling clearance optimization without modifying the part design
Solution Approach 2:
The patent introduces a new dimension of fiber orientation by depositing fibers at angles (e.g., 45° or 90°) relative to the roller axis rather than only parallel to the movement direction. This dimensional change in fiber placement allows the applicator head to navigate around complex geometries while maintaining proper fiber reinforcement orientations for structural integrity
2Device complexity
If fibers are deposited parallel to the movement of the applicator roller as in conventional methods, then the deposition process is simple, but the reinforcement orientation is limited and cannot achieve desired orientations for specific geometries
Solution Approach 1:
The patent makes the fiber orientation dynamic by allowing the fiber strip to be deposited at variable angles relative to the roller axis. The system can adjust fiber orientation angles (e.g., 0°, 45°, 90°) during the deposition process, enabling adaptation to different geometric requirements while maintaining a relatively simple applicator roller mechanism
Solution Approach 2:
The applicator roller is designed with multi-functionality to deposit fibers in multiple orientations (parallel, at angles, or transverse to movement direction) using the same device. This universal capability allows a single applicator roller system to handle various reinforcement patterns and complex geometries without requiring multiple specialized deposition mechanisms
3Productivity
If multiple layers of fibers are deposited simultaneously to reduce draping time, then productivity increases, but creases may form in the fiber layers
Solution Approach 1:
The patent applies partial action by depositing multiple fiber layers in a controlled sequence rather than all at once. The applicator roller can deposit one layer, then partially retract or adjust position before depositing the next layer, ensuring each layer is properly laid down without excessive tension that would cause creases, while still maintaining improved productivity compared to traditional single-layer deposition
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to an application head (1) for automatically applying fibres, which application head comprises at least: - an application roller (3) that is designed to apply fibres to a mould (F), which application roller is rotatably movable on its axis for applying fibres to the mould; and - a feed device (10) comprising a coil of a strip (12) of fibres (16) having a predefined orientation, the strip of fibres being configured to be transferred by unwinding the feed device onto the application roller with at least one portion of the fibres of the strip being oriented such that they are not perpendicular to the axis of the roller.