Continuous Fiber Preform Manufacturing via Transverse and Longitudinal Reshaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing fiber-reinforced plastic components with complex geometries are costly, time-consuming, and inefficient, particularly in aerospace and automotive industries, due to reliance on manual processes and limited automation for curved parts, which results in high production costs and weight.
Innovation Solution
A method and device for continuously reshaping and curving fiber layers into predetermined cross-sections using CNC-manufactured mold cores and pressure rollers, allowing for automatic production of complex components with dry fiber materials, and a modular system for continuous production of preforms with variable radii and lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If manual processes are used to produce fiber-reinforced plastic components with complex geometries, then geometric complexity and component stability are maintained, but production costs increase and productivity decreases
Solution Approach 1:
The production process is segmented into distinct automated stages: fiber layer feeding, transverse reshaping via pressure rollers, longitudinal curving, and matrix impregnation. This segmentation enables each stage to be optimized independently for automation while maintaining complex geometric outcomes.
Solution Approach 2:
Fiber layers are pre-aligned and pre-positioned on the drum before the forming process begins. The transverse reshaping and longitudinal curving are performed in predetermined sequences, allowing complex geometries to be achieved through automated execution of pre-planned forming actions rather than manual adjustment during production.
2Shape
If manual draping and sewing methods are used for curved components, then complex shapes are achieved, but production time increases and automation extent decreases
Solution Approach 1:
Manual draping and sewing operations are replaced by a mechanically automated system where pressure rollers perform transverse reshaping and the rotating drum performs longitudinal curving. The fiber layers are continuously fed and formed through coordinated mechanical action rather than manual manipulation, dramatically reducing production time while maintaining curved geometry capability.
Solution Approach 2:
The production process operates continuously with fiber layers being fed, reshaped, curved, and impregnated in an uninterrupted sequence. The drum rotation and pressure roller operation maintain continuous motion throughout the forming process, eliminating the start-stop nature of manual operations and enabling high-volume production of curved components.
3Productivity
If automated processes are used for simple geometries, then productivity increases, but geometric complexity and adaptability decrease
Solution Approach 1:
The forming system is made dynamic through adjustable pressure roller positions, variable drum rotation speeds, and controllable fiber layer tension. These dynamic parameters can be modified during operation to produce different cross-sections and curvature radii, enabling the same automated equipment to adapt to various geometric requirements while maintaining high productivity.
Solution Approach 2:
Geometric flexibility is achieved by changing process parameters such as pressure roller spacing, drum rotation speed, and fiber layer feed rate. By adjusting these parameters, the system can produce a range of cross-sectional shapes and curvature radii, transforming a simple automated line into a versatile forming system capable of handling multiple component types.
4Shape
If sewing is used to join fiber layers for complex components, then geometric complexity is achieved, but component stability decreases due to holes and seam weakness
Solution Approach 1:
The problematic sewing operation is completely extracted from the process. Instead of joining fiber layers through mechanical stitching that creates holes and weak points, the invention uses continuous matrix impregnation to bond fibers. The matrix material flows between and binds the fiber layers, eliminating seams and associated stability issues while maintaining complex structural integrity.
Solution Approach 2:
The matrix impregnation process creates a homogeneous bonding structure throughout the composite. The plastic matrix uniformly distributes between fiber layers, creating consistent adhesion without the localized stress concentrations that occur at sewn seams. This homogeneous bonding maintains component stability and strength throughout the entire structure.
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
Enables cost-effective, continuous, and automated production of complex fiber-reinforced plastic components with reduced weight and production time, using dry fiber materials and thermoplastic matrices, while maintaining component stability and geometric complexity.
Implementation Method 1
reshaping the supplied fiber layers into a predetermined cross-section by means of transverse reshaping
Implementation Method 2
curving the created profile into a predetermined radius by means of longitudinal forming
Data Source
Figure 1~3
Figure 4a~4b
Figure 5a~5c
AI summary
The method involves transforming continuously supplied fiber layers (16) e.g. braided fabrics, into a preset cross-section by transverse transformation. A developed profile is specifically curved by longitudinal transformation, where radius of the longitudinal transformation is variable. Preforms are assembled from profiles, which are formed in parallel. The fiber layers are mounted on rollers or coils and supplied from a provision device (2) for a manufacturing process. The fiber layers are pre-produced in an upstream manufacturing device in a continuous manner. An independent claim is also included for a device for continuous manufacturing of preforms from fiber reinforced plastic.