Fiber Strip Multiapplicator Head for Composite Laminates
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Solution Overview
Problem
Existing heads for applying carbon fiber or glass fiber strips in laminar parts often result in significant material waste, especially when edges are oblique or irregular, due to the need for multiple runs and inefficient cutting systems, which increases work time and decreases efficiency.
Innovation Solution
A head with a reel-holder system that feeds multiple spools of fiber strips to a compacting area where they are pressed together by a flexible roller, integrated with a selective cutting system using master rollers and blades, allowing for synchronized cutting and restarting of strips without reducing application speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wide strips are used to cover the entire surface with a minimum number of runs, then productivity is improved, but material waste increases significantly due to cuts for shaping edges
Solution Approach 1:
The patent applies segmentation by using multiple narrow fiber strips (e.g., 5-10 strips) instead of a single wide strip. Each strip can be independently controlled and cut, allowing the application to cover the entire surface area efficiently while minimizing waste through precise individual strip termination at part edges and hollows.
2Loss of substance
If narrow strips are used to reduce material waste through better edge adaptation, then material waste is reduced, but the number of runs increases and productivity decreases
Solution Approach 1:
The patent merges multiple narrow strip applications into a single simultaneous operation. The multi-applicator head applies several narrow strips (e.g., 5-10 strips) in one run, achieving the same coverage as would require many sequential runs with a single narrow strip, thereby maintaining productivity while minimizing waste through precise individual strip control.
Solution Approach 2:
The multi-applicator head performs multiple functions simultaneously: it applies multiple narrow strips in parallel, independently controls the start and end of each strip, and integrates a cutting system that can selectively cut individual strips. This multi-functionality allows the system to achieve both waste reduction and maintained productivity.
3Loss of substance
If multiple narrow strips are applied jointly in each run to reduce material waste, then material waste is reduced, but device complexity increases due to the need for synchronization with cutting systems
Solution Approach 1:
The patent introduces an intermediary mechanical linkage system that connects the cutting mechanism to the strip feeding system. This intermediary consists of synchronized gears and shafts that automatically coordinate the cutting action with the strip movement, eliminating the need for complex electronic sensors and control systems while achieving precise synchronization.
4Manufacturing precision
If a flexible roller pressure system is used to achieve uniform application of fiber strips, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs a flexible roller made of elastomeric material that conforms to the substrate surface geometry. This flexible shell automatically distributes pressure uniformly across the strip width and adapts to irregular surfaces without requiring complex pressure control mechanisms, sensors, or adjustable components, thereby achieving high manufacturing precision with minimal device complexity.
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 solution minimizes material waste and increases productivity by allowing precise cutting and restarting of fiber strips, enabling efficient application of strips with complex outlines and hollows without slowing down the process.
Implementation Method 1
The pressure system on the strips in the application area consists of a roller of flexible material capable of adapting to the surface to be taped
Implementation Method 2
The dividers included between the sheets have holes through which an injection of air acting as lubricant occurs, reducing the friction of the strips in the leading hollows
Data Source
AI summary
The invention relates to a fiber strip multiapplicator head of the type supplying multiple independent application strips, to be compacted jointly in an area (2) by means of a roller of flexible material, the independent strips being led through hollows defined by the structural formation of a body (3) in the sides of which assemblies are arranged, which assemblies comprise respective master rollers (4) for pulling the strips synchronized with the respective cutting systems (5).