Fibre Tow Distribution Apparatus for Pre-form Manufacturing
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Solution Overview
Problem
The traditional method of manufacturing pre-forms for wind turbine blades using endless sheets of fibers in resin results in significant waste, increased manufacturing costs due to time-consuming cutting, and issues with resin adherence and trapped air between layers.
Innovation Solution
An apparatus comprising a fibre tow distribution device, a retention device, and a manipulation device that allows for precise distribution and retention of fibre tows onto a work surface with applied resin, enabling efficient preparation of pre-forms with reduced waste and improved air removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If endless sheets of fibres in resin are cut into smaller parts to create pre-forms, then the required shape and size are achieved, but significant waste material is generated and manufacturing time increases
Solution Approach 1:
The fibre sheet is segmented into individual fibre tows that are distributed separately through distribution passages, allowing each tow to be precisely placed only where needed in the final pre-form configuration, eliminating the need to cut and discard excess material from large sheets
Solution Approach 2:
The fibre tows are pre-distributed onto the resin layer in the exact configuration required for the final pre-form before stacking and curing, ensuring that the correct shape and size are achieved from the beginning without subsequent cutting operations that would generate waste
2Manufacturing precision
If endless sheets of fibres in resin are cut into smaller parts to create pre-forms, then the required shape and size are achieved, but manufacturing time and costs increase
Solution Approach 1:
The fibre sheet is segmented into individual fibre tows that are distributed separately through distribution passages, allowing each tow to be precisely placed only where needed in the final pre-form configuration, eliminating the need to cut and discard excess material from large sheets
Solution Approach 2:
The fibre tows are pre-distributed onto the resin layer in the exact configuration required for the final pre-form before stacking and curing, ensuring that the correct shape and size are achieved from the beginning without subsequent cutting operations that would consume time
3Manufacturing precision
If pre-wetted sheets of fibres (pre-pregs) are cut into desired shapes, then the required shape is achieved, but resin adheres to the cutting device and waste material increases
Solution Approach 1:
The pre-preg sheet is segmented into individual fibre tows that are distributed separately through distribution passages, allowing precise placement without cutting operations, thereby eliminating resin adherence to cutting devices and reducing harmful waste material
Solution Approach 2:
The fibre tows are pre-distributed onto the resin layer in the exact configuration required for the final pre-form before stacking and curing, ensuring that the correct shape is achieved from the beginning without subsequent cutting operations that would cause resin adherence and generate harmful waste
4Manufacturing precision
If multiple layers of pre-pregs are stacked to create pre-forms, then the required thickness and structure are achieved, but air becomes trapped between layers
Solution Approach 1:
The fibre structure is segmented into individual tows distributed through separate passages, creating a more open and controlled layer structure that facilitates air evacuation during stacking and curing processes
Solution Approach 2:
Each distribution passage can be configured with specific characteristics (size, shape, orientation) to control the local arrangement of fibre tows, optimizing the layer structure for air removal while maintaining the required overall pre-form structure
Data Source
AI summary
An apparatus and a method for preparing a pre-form including at least one layer of fiber tows being at least partly fixed by a resin. The apparatus includes a work surface, a fiber tow distribution device, a fiber tow retention device, and a manipulation, device which is adapted to move the fiber tow distribution device relative to the fiber tow retention device. The apparatus is arranged so that free ends of the fiber tows can be delivered from the fiber tow distribution device to the fiber tow retention device, and the fiber tow retention device is adapted for retention of the free ends so that mutual movement of the fiber tow distribution device and the fiber tow retention device away from each other causes drawing of the fiber tows through distribution passage and distribution hereof onto the work surface.