Calculated Fiber Tow Angle for Uniform Preform
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Solution Overview
Problem
Conventional carbon fiber preform processing using circular needle looms generates waste when incorporating orthogonal structures, as disc shapes are punched from rectangular fabrics, leading to non-uniform fiber distribution and increased waste material.
Innovation Solution
Optimized fiber tow orientation is achieved by varying the angle of fiber tows from more radial at the inner diameter to more tangential at the outer diameter, ensuring substantially uniform thickness and areal weight across the preform, using a continuous fiber tow to form each layer without radial variations, thereby reducing waste and improving uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If disc shapes are punched from rectangular fabric using conventional circular needle loom, then the preform can be manufactured with orthogonal weave structure, but significant waste material is generated and fiber distribution becomes non-uniform
Solution Approach 1:
The patent applies parameter changes by varying the fiber tow angle as a function of radius from the inner diameter to the outer diameter of the preform. This angular variation compensates for the radial expansion of circumferential arcs, maintaining uniform areal weight and fiber distribution throughout the disc-shaped preform without generating waste material.
Solution Approach 2:
The patent utilizes the curved geometry of the circular needle loom to its advantage by implementing a calculated fiber tow angle that follows the radial curvature of the preform. The fiber angle θ varies continuously from the inner radius to the outer radius, creating a smooth curved fiber distribution pattern that matches the circular geometry and eliminates waste.
2Device complexity
If fiber tow angle is kept constant radially and circumferentially, then the manufacturing process is simple, but the preform exhibits non-uniform thickness and areal weight from ID to OD
Solution Approach 1:
The patent implements local quality by assigning different fiber tow angles to different radial positions within the preform. The fiber angle is optimized locally at each radius to compensate for the increasing circumferential length, ensuring that each local region contributes uniformly to the overall preform areal weight and thickness.
Data Source
AI summary
An optimized fiber tow orientation, to achieve substantially uniform fiber tow volume across the web, e.g., from inner diameter (ID) to the outer diameter (OD) of a disc shaped preform, without substantially varying the angles of the plurality of fiber tows radially or circumferentially is described herein. Utilizing the systems and processes described herein, a net shape preform may be created. A substantially continuous fiber tow may be used to form the preform. The fiber tow angle of each fiber tow may vary, from more radial, such as at the ID, to more tangential, such as at the OD, as the radius increases, such that there is substantially uniform thickness and substantially uniform areal weight from ID to OD of the preform or layer.