Fiber-Layer Tube Forming With Phase-Shifted Helical Fixing
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Solution Overview
Problem
Existing methods for producing tube bodies, such as power transmission shafts, face challenges in aligning fiber materials along the axial direction of a mandrel while maintaining low production costs, particularly when the orientation angle of the fibers is small, leading to fiber displacement due to gravity.
Innovation Solution
A method involving the formation of multiple fiber layers on a mandrel, with each layer fixed using a first fixing member that is wound helically around the mandrel, followed by resin impregnation and heating to mold the tube body, ensuring the fixing members are disposed at different phases along the axial direction to prevent fiber displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the filament winding technique is used to reduce production cost, then production cost is reduced, but fiber alignment along the axial direction becomes difficult
Solution Approach 1:
The fiber reinforcement is divided into multiple discrete fiber bodies arranged in specific patterns rather than continuous winding. Each fiber body is positioned independently to achieve precise axial alignment while using cost-effective discrete fiber placement instead of expensive continuous filament winding equipment
Solution Approach 2:
A resin-impregnated fiber structure is introduced as an intermediary between the mandrel and the final tube body. The fibers are embedded in resin to maintain their positional stability and axial alignment during the molding process, preventing displacement while using simpler discrete fiber placement methods
2Manufacturing precision
If the orientation angle of fibers is small to achieve axial alignment, then fiber alignment along axial direction is improved, but fiber displacement due to gravity increases
Solution Approach 1:
The adverse effect of gravity on fiber displacement is counteracted by introducing a resin matrix that surrounds and supports the fibers. The resin provides counterbalancing support to prevent gravity-induced displacement of fibers with small orientation angles, while maintaining their axial alignment configuration
Solution Approach 2:
A composite structure is formed by combining fibers with small orientation angles and a resin matrix. The resin-impregnated fiber composite maintains the stability of fibers at small orientation angles by providing structural support and preventing gravity-induced displacement, while preserving the axial alignment benefits
3Strength
If multiple fiber layers are stacked to improve structural stability, then tube body structure is strengthened, but production complexity increases
Solution Approach 1:
Multiple fiber layers are combined and integrated into a single resin-impregnated structure during the molding process. The resin matrix merges the discrete fiber layers into a unified composite structure, achieving enhanced strength while simplifying the production process by consolidating multiple layers into one integrated forming operation
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 reduces fiber displacement and maintains low production costs by effectively aligning fibers along the axial direction, even at small orientation angles, resulting in a stable tube body structure.
Implementation Method 1
a molding step of, after the step of repeating the fiber layer forming step, impregnating the fiber bodies of the plurality of fiber layers with a resin on the outer circumferential surface of the circular cylindrical tube member and then heating the resin to mold the resin
Data Source
AI summary
A tube body production method includes repeating a fiber layer forming step to form fiber layers so that the fiber layers are disposed in a manner of being stacked in a radial direction of a cylindrical tube member. Each fiber layer forming step includes, to form a current fiber layer: disposing a respective fiber body with respect to an outer circumferential surface of the cylindrical tube member so that the respective fiber body extends in an axial direction of the cylindrical tube member; and winding a respective first fixing member with respect to the outer circumferential surface of the cylindrical tube member such that the respective first fixing member is wound over the respective fiber body by one or more turns in a circumferential direction, along the axial direction of the cylindrical tube member, at a different phase with respect to the first fixing members disposed for other fiber layers.