Fibre Interlayers for Automated Thermoplastic Composite Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing composite components, such as Carbon Fiber Reinforced Plastic (CFRP), are labor-intensive and costly, and lack the ability to optimize local thermal and mechanical properties effectively, especially in complex shapes and high-temperature applications.
Innovation Solution
A method and apparatus for forming multi-layer thermoplastic components by sequentially laying thermoplastic and pre-impregnated fibers in an inline process, allowing for control of mechanical and thermal properties on a layer-by-layer basis, using a combination of short and continuous fibers in various orientations, and enabling the adjustment of thermal expansion coefficients and material properties to meet specific part requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lay-up methods are used to manufacture composite components, then high manufacturing precision and accuracy can be achieved, but the process becomes highly labor intensive and time consuming
Solution Approach 1:
The patent replaces manual mechanical lay-up operations with an automated extrusion system that deposits thermoplastic material and fibers layer by layer. The extruder mechanism automatically positions and bonds layers according to digital models, eliminating manual labor while maintaining precision through computer-controlled deposition parameters.
Solution Approach 2:
The invention changes the manufacturing parameters from manual process control to automated extrusion parameters including temperature, pressure, and deposition speed. By controlling the extrusion temperature and layer thickness parameters, the system achieves both high precision and increased productivity through consistent, repeatable deposits.
2Productivity
If auto-lay-up machines are used to decrease manufacturing times, then productivity increases, but device complexity and costs dramatically increase
Solution Approach 1:
The patent segments the composite manufacturing process into distinct functional steps: thermoplastic extrusion, fiber placement, and bonding. This segmentation allows each function to be performed by simple, dedicated mechanisms rather than requiring a single complex auto-lay-up machine, reducing overall system complexity while maintaining productivity.
Solution Approach 2:
The invention merges the thermoplastic extrusion and fiber placement operations into a single integrated extrusion head assembly. This combination eliminates the need for separate positioning and bonding systems, reducing device complexity while achieving automated layer-by-layer construction.
3Adaptability or versatility
If conventional composite manufacturing methods are used, then standard components can be produced, but the ability to optimize local regions for thermal and mechanical properties is limited
Solution Approach 1:
The patent implements local quality optimization by allowing different fiber orientations, densities, and thermoplastic compositions in different regions of the component. The extrusion system can vary fiber alignment and material properties layer by layer according to the specific mechanical and thermal requirements of each zone, creating customized local properties without complicating the overall manufacturing process.
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 approach enables the creation of complex components with optimized mechanical and thermal properties, reducing manufacturing costs and time, while allowing for high-dimensional accuracy and scalability in 3D printing, even at high temperatures, by providing a highly controllable and adaptable process.
Implementation Method 1
a first extruder arranged to extrude a thermoplastic material in a controlled manner
Implementation Method 2
a second extruder arranged to extrude a fibrous material containing a thermoplastic material and compress the fibrous material onto the first layer
Implementation Method 3
The resulting structure is then cured, for example in an autoclave, to allow for consolidation of the resin which can also harden
Data Source
AI summary
A method of forming a multi-component composite material additive manufacture apparatus is described along with an apparatus therefor. The process involves laying a plurality of materials as part of the same process with a range of continuous and discontinuous fiber reinforcement options designed to optimize the operational capabilities of a component.