Fiber Preform Production via Strand Splitting and Deposition
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Solution Overview
Problem
Current methods for producing fiber preforms with high fiber volume fractions are costly and inefficient, as they often require high-priced source materials and result in low fiber volume percentages, leading to weak points in composite components.
Innovation Solution
A method involving the deposition of reinforcing fiber bundles with a binder, where continuous ribbon-shaped strands are split into partial strands and cut to length, allowing for high fiber volume percentages while reducing filament counts, using a deposition device with a spreader unit, longitudinal splitting device, and cut-to-length unit to achieve cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-priced source materials with low filament counts are used to achieve high fiber volume fractions, then the mechanical characteristics of composite components are improved, but the production costs increase significantly
Solution Approach 1:
The patent applies segmentation by dividing a continuous high-linear-density fiber strand into multiple separate fiber bundles through a splitting device. This allows one expensive high-quality strand to be distributed across multiple bundles, effectively reducing the cost per bundle while maintaining the ability to achieve high fiber volume fractions when multiple bundles are deposited together. The splitting process transforms a single costly resource into multiple usable units.
Solution Approach 2:
The patent changes the parameter of fiber bundle configuration by depositing multiple split bundles simultaneously or in sequence to achieve high fiber volume fractions. Instead of using single low-filament-count bundles, the system uses multiple bundles whose combined filament counts achieve the desired volume fraction while keeping individual bundle costs manageable. This parameter change in bundle arrangement resolves the cost-strength contradiction.
2Productivity
If automated deposition processes with cutting devices are used to produce fiber preforms, then productivity is improved, but device complexity and production costs increase
Solution Approach 1:
The patent merges multiple functions into a single integrated deposition head that combines the spreader unit, longitudinal splitting device, cut-to-length unit, and deposition mechanism. By combining these functions in one device, the system achieves automated high-productivity production without requiring multiple separate machines or complex coordination systems. The merged device reduces overall system complexity while maintaining high productivity.
Solution Approach 2:
The deposition head is designed as a universal device that performs multiple operations: spreading fibers, splitting strands longitudinally, cutting to length, and depositing bundles. This multi-functional device replaces what would otherwise require several separate specialized devices, reducing device complexity while maintaining automated productivity. The universal deposition head can handle various fiber types and deposition patterns.
3Strength
If fiber bundles with low filament counts are used to achieve high fiber volume fractions, then mechanical characteristics are improved, but the cost of source materials increases
Solution Approach 1:
The patent segments a single high-linear-density strand into multiple lower-filament-count bundles through the longitudinal splitting device. This segmentation allows the expensive high-quality fiber material to be distributed across multiple bundles, reducing the cost per bundle while maintaining the total filament count needed for high fiber volume fractions. Multiple segmented bundles are then deposited to achieve the desired mechanical characteristics.
4Productivity
If continuous ribbon-shaped strands are split into multiple partial strands, then the utilization of high linear density reinforcing fiber yarns is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent combines the spreading and splitting functions into an integrated unit where the spreader unit and longitudinal splitting device work together in a coordinated manner. This merged approach simplifies the manufacturing process by eliminating the need for separate spreading and splitting operations, reducing process complexity while maintaining high material utilization efficiency. The combined unit processes continuous strands through spreading and splitting in one continuous operation.
Data Source
AI summary
Described is a method for producing a fiber preform by deposition of reinforcing fiber bundles onto a surface including: supplying at least one continuous strand of reinforcing fibers provided with a binder to a deposition head, spreading the at least one strand in a spreader unit and conveying using a first conveying device to a longitudinal splitting device, cutting the at least one strand in the longitudinal splitting device along the longitudinal extension thereof into at least two partial strands by means of a splitting element, conveying the partial strands by means of a second conveying device to a cut-to-length unit, cutting the partial strands by means of the cut-to-length unit into reinforcing fiber bundles, and depositing the reinforcing fiber bundles onto a surface and/or reinforcing fiber bundles deposited on the surface and fixing the reinforcing fiber bundles to form the fiber preform.