Fibre-Reinforced Flange Manufacturing via Dynamic Winding
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Solution Overview
Problem
Existing methods for manufacturing fibre-reinforced flanges, especially for larger diameters, are costly and limited by practical constraints in reinforcement placement and orientation, leading to inefficiencies in structural performance.
Innovation Solution
A method involving the alternating winding of fibre-reinforcing tapes around a tubular member, impregnated with thermosetting resin, to create a laminated structure that is then cut to form flange and hub sections, allowing for optimized fibre placement and orientation, resulting in cost-efficient and reliable production of fibre-reinforced flanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to manufacture fibre-reinforced flanges for larger diameters, then production cost increases, but structural efficiency and reliability deteriorate due to practical constraints in reinforcement placement and orientation
Solution Approach 1:
The invention transitions from static, pre-placed reinforcement layers to a dynamic winding process where fibres are continuously laid in optimized patterns during manufacturing. This allows the reinforcement orientation to adapt to the specific structural requirements of each flange section, improving both reliability and cost-effectiveness for larger diameters
Solution Approach 2:
The invention changes the manufacturing parameters by using automated winding equipment that can precisely control fibre placement angles, densities, and orientations. This enables optimization of the reinforcement structure according to the specific load requirements of each flange section, rather than using fixed traditional patterns
2Strength
If reinforcement layers are tightly wound to improve structural strength, then manufacturing complexity increases due to precise placement requirements
Solution Approach 1:
The winding system is designed to be self-regulating, where the tension and placement of each fibre layer automatically prepares the surface for the next layer. The process inherently ensures proper placement and orientation without requiring complex external control mechanisms for each individual layer
Solution Approach 2:
The invention employs continuous winding of reinforcement fibres around the flange structure, eliminating the discontinuous placement and alignment steps required in traditional methods. This continuous process maintains constant tension and orientation control, achieving high strength without proportionally increasing manufacturing 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 method enables the fast, cost-effective, and reliable manufacturing of fibre-reinforced flanges with optimized fibre placement and orientation, improving structural efficiency and reducing production costs, particularly for larger diameters.
Implementation Method 1
said sheet elements being impregnated by a thermosetting resin
Data Source
AI summary
A method of manufacturing at least one flange by first rotating a tubular element and two sheet elements with respect to one another until a radially enlarged portion and adjacent hub section have been formed on the tubular element. The sheet element is impregnated by a thermosetting resin. When the resin has cured, the radially enlarged portion is cut along a cut line, thereby also dividing the tubular element in two parts and generating at least a first flange having a first flange section and a first hub section. Optionally, a second flange having a second flange section and a second hub section, is generated. In a preferred embodiment, the cut line is arranged in the middle of the radially enlarged portion, whereby two similar flanges are generated.