Fiber Laminate Taper Section with Constant Density
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Solution Overview
Problem
Fiber laminates with continuously changing thicknesses experience variations in physical properties due to differing numbers of stacked layers and fiber orientations, leading to inconsistent strength and shape-imparting properties.
Innovation Solution
A fiber laminate with a taper section is created by stacking fiber layers with continuously changing thicknesses, where the orientation angles of discontinuous fibers are aligned in different directions, and the density is kept constant throughout, using a web drafter with differentiated roller groups to maintain uniform fiber density and thickness changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the thickness of the fiber laminate is continuously changed by shifting the ends of fiber layers, then the shape-imparting properties are improved, but the physical properties vary due to different numbers of stacked layers and changing fiber orientations
Solution Approach 1:
The invention applies different fiber orientation angles in different regions of the fiber laminate. Specifically, in the thickness changing section, the fiber orientation angle is set to 0° (parallel to the reference line), while in other sections different angles are used. This local differentiation allows the laminate to maintain consistent physical properties in the taper region while still achieving continuous thickness variation for shape imparting.
Solution Approach 2:
The invention changes the fiber orientation angle parameter strategically to resolve the contradiction. By setting the fiber orientation angle to 0° specifically in the thickness changing section where the number of stacked layers varies, the invention maintains consistent physical properties despite the continuous thickness change. This parameter change allows simultaneous achievement of shape imparting and physical property stability.
2Shape
If the thickness of the fiber laminate is continuously changed, then the shape-imparting properties are improved, but resin-rich portions form due to varying numbers of stacked layers
Solution Approach 1:
The invention applies a specific fiber orientation (0° parallel to reference line) locally in the thickness changing section to prevent resin-rich portion formation. This localized approach ensures that resin distribution remains uniform despite the continuous thickness variation, maintaining structural integrity while achieving the desired shape imparting properties.
3Shape
If the ends of fiber layers are shifted to change thickness, then the shape-imparting properties are improved, but the fiber orientation changes and physical properties vary
Solution Approach 1:
The invention maintains consistent fiber orientation (0° parallel to reference line) specifically in the thickness changing section, while allowing different orientations in other sections. This localized orientation control ensures manufacturing precision and consistent physical properties in the critical taper region, while still enabling continuous thickness change for shape imparting.
Data Source
AI summary
A fiber laminate W is configured by laminating first to fourth fiber layers. The fiber laminate is provided with a taper section, in which the thickness changes depending on the position in the longitudinal direction. The first to fourth fiber layers are formed by discontinuous fibers and are configured with the orientation angles of the discontinuous fibers aligned in one direction. The orientation angles of the discontinuous fibers in the first to fourth fiber layers are different. In addition, the first to fourth fiber layers are provided with thickness changing sections, in which the thickness changes continuously while the density of fibers is kept constant irrespective of the position in the longitudinal direction. The taper section is configured by stacking the thickness changing sections. The change amount of the thickness of each thickness changing section is the same irrespective of the position in the longitudinal direction.