Fiber Preform Production via Integrated Pressing and Binder Activation
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Solution Overview
Problem
Existing processes for producing fiber preforms are time-consuming and require high capital expenditure due to numerous sequential steps and the need for multiple workstations.
Innovation Solution
A process where dry textile fiber material is dimensioned into individual layers, layered, and pressed to form interconnected preforms, with binder activation and separation achieved in a single step, using techniques like ultrasound or conductive heat transfer for binder activation and precise cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sequential process steps are used for fiber preform production (dimensioning, layering, pressing, separating, binder activation), then each step can be performed with dedicated equipment ensuring quality, but the production time increases and productivity decreases
Solution Approach 1:
The patent combines multiple sequential process steps (separation of interconnected fiber preforms and activation of binder) into a single integrated process step. The pressing operation simultaneously performs both separation and binder activation functions, eliminating the need for separate workstations and reducing production time while maintaining quality standards through controlled pressing parameters.
Solution Approach 2:
The pressing operation is designed to perform multiple functions simultaneously: it separates the interconnected fiber preforms from each other and activates the binder in the same process step. This multi-functional approach reduces the number of required workstations and streamlines the production process.
2Manufacturing precision
If multiple dedicated workstations are used for each process step, then each operation can be optimized independently, but the capital expenditure and device complexity increase
Solution Approach 1:
The patent merges the functions of separate workstations into a single integrated pressing operation. Instead of having dedicated equipment for separation and binder activation, the pressing step performs both functions simultaneously, reducing device complexity and capital expenditure while maintaining process optimization through controlled parameters.
Solution Approach 2:
The pressing workstation is designed as a universal device that performs multiple operations (separation and binder activation) that previously required separate dedicated equipment. This reduces the total number of workstations needed while maintaining the ability to optimize each function through pressing parameter control.
3Reliability
If multiple sequential process steps are implemented, then each step can be controlled independently for quality, but the number of workstations and capital expenditure increase
Solution Approach 1:
The patent combines process control for separation and binder activation into a single integrated control system for the pressing operation. This reduces the number of independent control systems needed while maintaining reliable process control through unified parameter management, thereby reducing device complexity and capital expenditure.
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 significantly reduces production time, increases output, and lowers costs by minimizing the number of workstations required, while allowing for tailored fiber orientation and component properties.
Implementation Method 1
separation of the plurality of interconnected fiber preforms and an activation of the binder are achieved together in a single process step
Implementation Method 2
conductive heat transfer for binder activation
Data Source
AI summary
The disclosure relates to a method for producing a fiber preform, wherein: at least one dry and textile fiber material is provided; the fiber material is assembled into a plurality of individual layers; the plurality of individual layers is provided with a binder; the plurality of individual layers is layered to form a package; and a plurality of interconnected fiber preforms is formed by pressing the package. A separation of the plurality of interconnected fiber preforms and activation of the binder occur in a common process step. The disclosure furthermore relates to a corresponding system.