FMV Hybrid Component Braiding and Reshaping

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Solution Overview

Problem

Existing methods for producing fibre matrix composite (FMV) components suffer from decreased mechanical properties and limited reshaping capabilities due to repeated thermoplastic melting and friction-related damage during the removal of moulded hoses, which restricts high degrees of reshaping and leads to compromised quality.

Innovation Solution

A method involving braiding a dry hybrid fibre thread onto a lost core element, reshaping and consolidating the fibre core composite, where the core element remains integral and the hybrid fibre braid is impregnated, allowing for high degrees of reshaping, including bending angles less than 150°, and using magnetically effective particles for inductive heating to avoid material impairment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the moulded hose is removed from the finished component after reshaping, then the component can be assembled, but damage to the moulded hose and/or FMV material occurs due to friction during reshaping

Engineering Contradiction:

Improveremoval of moulded hoseVSAvoidquality of moulded hose and FMV material

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention extracts and removes the moulded hose from the production process entirely. Instead of removing it after reshaping, the hose is not used at all - a lost core element is used instead, which is completely consumed during the braiding process and leaves no residue that needs removal.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The lost core element is designed as a disposable component that is completely consumed during the braiding process. It serves its purpose during manufacturing and is then discarded, eliminating the need for removal operations and associated damage risks.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If semi-finished products are completely impregnated and consolidated before reshaping, then material quality is maintained, but only considerably greater bending angles can be achieved

Engineering Contradiction:

Improvematerial qualityVSAvoiddegree of reshaping

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The invention performs the braiding operation before impregnation and consolidation. By braiding the hybrid fibre thread onto the lost core element first, the structure is formed while still flexible, allowing for high degrees of reshaping. Only after reshaping is complete is the impregnation and consolidation applied, maintaining material quality while achieving the desired geometry.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention exploits the dynamic state of the hybrid fibre thread during braiding - the thread is in a flexible, unconsolidated state that allows it to be shaped into complex geometries with bending angles of less than 150°. After braiding, the thread is then consolidated to lock in the desired shape, maintaining both flexibility during forming and structural integrity in the final product.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If repeated melting of the thermoplastic part is performed during production, then the component can be formed, but mechanical properties deteriorate

Engineering Contradiction:

Improveforming of componentVSAvoidmechanical properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention replaces the traditional thermoplastic melting and re-solidifying process with a mechanical braiding process. The hybrid fibre thread is braided onto the lost core element to form the component structure, eliminating the need for repeated melting operations that would degrade mechanical properties. The thermoplastic matrix is applied only once after braiding to bind the fibres together.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 production of FMV hybrid components with enhanced mechanical properties and high reshaping capabilities while maintaining material quality, reducing the risk of damage and oxidative processes, and facilitating cost-effective and efficient production.

Implementation Method 1

A dry hybrid fibre thread is braided onto a lost core element, such that a hybrid fibre braid is formed on the core element

Methodology Applied

Scientific EffectBraiding:

Implementation Method 2

The fibre core composite, which has the core element and the hybrid fibre braid, is reshaped

Methodology Applied

Scientific EffectMechanical deformation: Deformation

Implementation Method 3

the hybrid fibre braid is impregnated and consolidated on the core element

Methodology Applied

Scientific EffectImpregnation: Absorption (physical)

Implementation Method 4

the hybrid fibre braid is impregnated and consolidated on the core element

Methodology Applied

Scientific EffectConsolidation:

Implementation Method 5

using magnetically effective particles for inductive heating to avoid material impairment

Methodology Applied

Scientific EffectInductive heating: Induction Heating

Data Source

PatentUS10906252B2Method for the production of an FMV hybrid component, and FMV hybrid component

Publication Date: 2021.02.02 MERCEDES BENZ GROUP AG

AI summary

A method for the production of an FMV hybrid component includes braiding a dry hybrid fibre thread onto a core element, where a hybrid fibre braid is formed, and obtaining a fibre core composite. The method further includes reshaping the fibre core composite and impregnating and consolidating the hybrid fibre braid on the core element.