Fiber Mat Preparation with Suction Apertures for Matrix Penetration

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Solution Overview

Problem

Existing methods for preparing semifinished products made of fiber material prior to wet-pressing processes are complex and costly, especially for thick products, as they require multiple stacks and sandwich-like introduction of matrix substance, increasing production time and costs.

Innovation Solution

A method involving a preparation device with a surface of numerous suction apertures applies negative pressure to the underside of the semifinished product, allowing the flowable matrix substance to be introduced exclusively through the upper side, assisted by capillary forces and gravity, ensuring adequate penetration regardless of thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple individual semifinished product stacks are produced and arranged in a sandwich-like fashion to adequately saturate thick semifinished products, then the saturation quality is improved, but the production complexity and time increase significantly

Engineering Contradiction:

Improvesaturation qualityVSAvoidproduction complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention divides the preparation surface into multiple independently controllable suction zones with separate suction apertures. This allows different vacuum levels to be applied to different regions of the semifinished product simultaneously, enabling adequate saturation of thick products without needing to create multiple stacks. Each zone can be optimized for local saturation requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a single-direction matrix substance introduction (top-down only) to a multi-dimensional approach by introducing matrix substance from both the upper side and the lower side (through the preparation surface). This dual-directional introduction ensures thorough saturation of thick semifinished products while maintaining a single-stack configuration, avoiding the complexity of multiple stacks.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

Engineering Contradiction:

Improvesaturation qualityVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention enables continuous and simultaneous matrix substance introduction from both upper and lower sides of the semifinished product through multiple suction zones. This parallel processing approach saturates the entire product in a single operation rather than requiring sequential processing of multiple stacks, significantly reducing production time while maintaining saturation quality.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

By segmenting the preparation surface into multiple independently controllable suction zones, the system can simultaneously introduce matrix substance into different regions of the semifinished product through the lower side. This parallel saturation approach eliminates the need to produce and process multiple stacks sequentially, thereby reducing production time.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

Engineering Contradiction:

Improvesaturation qualityVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The preparation surface with multiple suction zones serves multiple functions simultaneously: it introduces matrix substance from the lower side, applies differential vacuum to different regions, and supports thick semifinished products. This multi-functional device eliminates the need for multiple separate processing steps and equipment that would be required for producing and assembling multiple stacks, thereby reducing production costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the functions of producing, saturating, and preparing multiple stacks into a single integrated process. By combining upper-side and lower-side matrix substance introduction in one operation, the system eliminates the need for separate production and assembly steps for multiple stacks, reducing both equipment and operational costs.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of operation

If the matrix substance is introduced exclusively via the upper side without negative pressure assistance, then the process is simple, but the penetration into thick semifinished products is inadequate

Engineering Contradiction:

Improveprocess simplicityVSAvoidpenetration quality

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The invention uses pneumatic vacuum suction through the preparation surface to actively draw matrix substance into the semifinished product from the lower side. This pneumatic assistance enhances penetration into thick products without complicating the upper-side introduction process, maintaining simplicity while improving saturation quality through the combined action of gravity, capillary forces, and vacuum suction.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The invention adds a lower-side introduction dimension to the traditional upper-side-only approach. By introducing matrix substance from both upper and lower sides simultaneously, the system achieves thorough penetration of thick semifinished products while keeping the process relatively simple through the use of vacuum-assisted passive uptake.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 and cost-effectively introduces the matrix substance into semifinished products of varying thicknesses and geometries, reducing production complexity and time, while enabling efficient saturation and curing within the wet-pressing process.

Implementation Method 1

applying a negative pressure to the underside of the semifinished product via the suction apertures

Methodology Applied

Scientific EffectNegative pressure: Pressure Gradient

Implementation Method 2

arranging a semifinished product made of fiber material with the underside on a preparation surface having a large number of suction apertures

Methodology Applied

Scientific EffectSuction: Suction

Implementation Method 3

introducing a flowable matrix substance via the upper side of the semifinished product

Methodology Applied

Scientific EffectCapillary forces: Capillary Action

Implementation Method 4

introducing a flowable matrix substance via the upper side of the semifinished product

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS10773507B2Method for the preparation of a semifinished product made of fiber material prior to a wet-pressing process

Publication Date: 2020.09.15 BAYERISCHE MOTOREN WERKE AG

AI summary

A method is provided for the preparation of a semifinished product made of fiber material with an upper side and with an underside prior to a wet-pressing process. The method includes following steps: arrangement of a semifinished product made of fiber material with the underside on a preparation area with a large number of suction apertures, application of a reduced pressure to the underside of the semifinished product by way of the suction apertures, and introduction of a flowable matrix material by way of the upper side of the semifinished product.