Continuous Fiber Ribbon Laminate Forming With Low Waste
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Solution Overview
Problem
Current methods for producing fiber-reinforced composite components are inefficient due to complex production processes, high fiber waste, and limited flexibility in shaping, particularly when using prepregs and infusion processes, which hinder productivity and increase costs.
Innovation Solution
A method for continuous production of laminates from unidirectionally embedded fiber slivers in a plastic matrix, involving transport, consolidation, and shaping, with options for various joining techniques and thermal treatment, allowing for flexible shaping and reduced cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If embroidery or sewing techniques are used to fix reinforcing fibers to an embroidery base, then the fiber structure can be precisely positioned according to analytical component calculation, but an additional impregnation process step is required that significantly increases cycle times
Solution Approach 1:
The patent combines the fiber positioning function and the structural support function into a single integrated textile reinforcement structure. The textile preform is designed to provide both precise fiber placement according to force flow analysis and inherent structural stability, eliminating the need for separate embroidery base and impregnation steps. This merging of functions directly resolves the contradiction by achieving precise positioning without adding time-consuming impregnation processes.
Solution Approach 2:
The textile reinforcement structure is pre-formed with the exact fiber arrangement and geometric configuration needed for the final component. The force flow analysis is translated into the textile structure design before manufacturing, so that when the preform is placed in the mold, the fibers are already in their final positions. This preliminary action eliminates the need for subsequent impregnation and repositioning steps, reducing cycle time while maintaining positioning precision.
2Reliability
If infusion processes (RTM, SRIM, vacuum injection) are used for subsequent impregnation of the fiber structure, then the polymer matrix can be injected under pressure and cured under heat and pressure, but the processes are relatively complex and result in low productivity due to long production cycles
Solution Approach 1:
The patent employs a continuous fiber reinforcement structure where fibers are laid in a continuous manner without interruption or discontinuous joining operations. This continuity allows the impregnation process to proceed smoothly and continuously, eliminating the start-stop nature of traditional infusion processes. The continuous structure enables sustained resin flow and uniform impregnation, improving both quality and productivity by maintaining continuous useful action throughout the manufacturing process.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the manufacturing process, including using specific temperature ranges for thermoplastic matrix materials (50-500°C melting points), controlling resin injection pressure, and optimizing curing conditions. By carefully selecting and controlling these parameters, the process achieves reliable matrix impregnation and curing while significantly reducing cycle times compared to traditional infusion methods, thus resolving the contradiction between quality and productivity.
3Ease of manufacture
If prepregs are used for fiber reinforcement, then the fibers are pre-impregnated with matrix material, but the semi-finished product is only suitable for geometrically simple structures and requires very high consumption of fiber material due to cutting to desired contours that generates corresponding fiber waste
Solution Approach 1:
The patent divides the manufacturing process into distinct stages: first creating the textile reinforcement structure with precise fiber arrangement, then separately injecting the matrix material during molding. This segmentation allows the fiber structure to be designed and prepared independently without pre-impregnation, enabling complex geometries to be formed without cutting and waste. The fibers are only used where needed in the final component geometry, eliminating the material waste associated with prepreg cutting.
Solution Approach 2:
The patent uses a dynamic, adaptable textile reinforcement structure that can be configured for complex three-dimensional geometries rather than being limited to simple shapes. The textile preform can be tailored to match the exact geometry of the final component, allowing continuous fiber placement that adapts to complex contours without requiring cutting or trimming operations. This dynamic adaptability eliminates fiber waste while maintaining ease of manufacture.
4Ease of manufacture
If continuous fiber strands are laid on top of each other to form a continuous support structure and pressed together with a shape-forming, long-fiber-reinforced compound in a mold, then structural components can be manufactured, but it is not possible to create a defined, one-piece structural component, producible in a single pressing step, that contains an integrated, precisely defined, and positionally optimized continuous fiber reinforcement structure
Solution Approach 1:
The textile reinforcement structure serves multiple functions simultaneously: it provides continuous fiber reinforcement, defines the geometric shape of the component, positions fibers according to force flow analysis, and acts as the final structural element without requiring separate impregnation or assembly steps. This multi-functionality enables the creation of a defined, one-piece structural component in a single pressing step with integrated, precisely defined fiber reinforcement, resolving the contradiction between ease of manufacture and manufacturing precision.
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 method enables high productivity and flexibility in producing laminates with complex geometries, minimizing fiber waste and cycle times, while maintaining mechanical properties, thus optimizing the production of lightweight composite components.
Implementation Method 1
The plastic matrix of the fiber tapes is particularly preferably melted, pressed in the molten state, and then solidified by cooling
Implementation Method 2
thermal treatment in the pretreatment station, whereby at least partial melting of the polymer matrix occurs
Implementation Method 3
pressed in the molten state, and then solidified by cooling
Implementation Method 4
solidification to form the laminate occurs through cooling of the polymer matrix
Implementation Method 5
the laminate is deformed by means of at least two forming units, in particular forming rollers, by positioning the forming units behind the consolidation units
Data Source
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AI summary
The method involves providing a set of forming rollers in a set of positions (9a, 9b), and transporting a set of fiber ribbons to a respective material storage that is arranged with a set of feed rollers for an assembly station. A layer-like merging of the set of fiber ribbons is performed in the assembly station with two consolidation units. The set of fiber ribbons is added by the two consolidation units so as to form a continuous laminate (6). The continuous laminate formed by the fiber ribbons is solidified. An independent claim is also included for a laminate.