Fiber Structure Width Variation Uniform Thickness
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Solution Overview
Problem
Fiber-reinforced composite materials with varying fiber widths exhibit non-uniform physical properties due to changes in fiber alignment and thickness, affecting their mechanical performance and impact absorption capabilities.
Innovation Solution
A fiber structure with a sectoral shape is manufactured using a drafting apparatus to align discontinuous fibers uniformly, ensuring continuous width variation and constant thickness, which maintains consistent fiber alignment and density across sections, thereby stabilizing physical properties and enhancing impact energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the width of the fiber element is changed by passing through a variable throat, then the fiber element obtains continuous width variation, but the thickness becomes non-uniform and fiber alignment varies
Solution Approach 1:
The patent changes the parameters of the die structure, specifically using a die with a varying opening width that corresponds to the desired fiber element width distribution. This allows continuous width variation while maintaining uniform thickness by controlling the forming process parameters rather than mechanically constraining the fiber element during forming.
Solution Approach 2:
The patent performs preliminary alignment of discontinuous fibers in the longitudinal direction before forming. By pre-aligning the fibers and preparing the die structure in advance, the process achieves both continuous width variation and uniform thickness without requiring post-forming adjustments or complex mechanical constraints during the forming process.
2Shape
If the width of the fiber element is changed by passing through a variable throat, then the fiber element obtains continuous width variation, but the fiber alignment varies from section to section
Solution Approach 1:
The patent performs preliminary alignment of discontinuous fibers in the longitudinal direction before forming. By pre-aligning the fibers using a alignment section in the die, the process ensures consistent fiber alignment throughout the formed fiber element even as the width varies continuously, preventing variation in fiber orientation from one section to another.
Solution Approach 2:
The patent controls the forming process parameters by using a die with a specifically designed opening width that matches the desired fiber element width distribution. This parameter control allows the fiber element to achieve continuous width variation while maintaining uniform fiber alignment through the entire length.
3Stability of the object's composition
If discontinuous fibers are aligned uniformly using a drafting apparatus, then fiber alignment and density become consistent, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the fiber alignment function and the forming function into a single integrated die structure. The die includes both an alignment section for aligning discontinuous fibers and a forming section for shaping the fiber element, eliminating the need for separate drafting apparatus and simplifying the overall manufacturing process while achieving uniform fiber alignment and density.
Data Source
Figure 1~2B
Figure 3A~3B
Figure 4A~5
AI summary
A fiber structure for a fiber-reinforced composite material includes a section in which a width varies continuously along a central axis in a plan view. In a section in which the width increases continuously along the central axis, discontinuous fibers are aligned radially along the central axis, and both a thickness of the fiber structure and a density of the discontinuous fibers are uniform.