Pillar-Stitched Glass Fiber Nonwoven for Stable Draping

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Solution Overview

Problem

Glass fiber rovings in unidirectional non-crimp fabrics are difficult to handle due to their smooth surfaces, leading to slipping and sliding during processing, which complicates the draping and handling of these fabrics, especially in complex components.

Innovation Solution

A unidirectional non-crimp fabric of glass fiber rovings with two stabilization layers on either side, stitched together by pillar stitching, improves handling and drapability, enhancing mechanical properties and impregnability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If glass fiber rovings are used in unidirectional non-crimp fabrics, then cost is reduced compared to carbon fibers, but handling difficulty increases due to smooth surfaces causing slipping and sliding

Engineering Contradiction:

Improvehandling stabilityVSAvoiddrapability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Stabilization layers are introduced as intermediary elements between the glass fiber rovings and the processing equipment. These stabilization layers provide friction and mechanical interlocking that prevent slipping and sliding of the smooth glass fibers during handling and draping operations

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The surface characteristics of the fabric are modified by adding stabilization layers that change the friction parameters and mechanical interlocking properties. This allows the smooth glass fiber rovings to be held in position during processing without changing the glass fibers themselves

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If glass fiber rovings with smooth surfaces are used, then manufacturing cost is reduced, but fiber slippage during feeding and stitching increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidfiber position stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

Stabilization layers act as intermediary elements that provide mechanical interlocking and friction to prevent fiber slippage during feeding and stitching operations, while allowing the use of cost-effective glass fiber rovings with smooth surfaces

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fabric is segmented into multiple functional layers: the glass fiber roving layer for reinforcement and the stabilization layers for handling control. This segmentation allows each layer to perform its specific function independently

Inventive Principle:

Principle #1Segmentation

3Reliability

If stabilization layers are added to prevent fiber slippage, then handling stability improves, but fabric complexity increases

Engineering Contradiction:

Improvehandling stabilityVSAvoidfabric structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The stitch density is optimized to provide sufficient stabilization without excessive complexity. By adjusting this parameter, the fabric achieves handling stability with a practical level of structural complexity that does not overly complicate manufacturing or final application

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12480238B2Unidirectional laid nonwoven and use thereof

Publication Date: 2025.11.25 SAERTEX GMBH & CO KG

AI summary

For the production of components made of fiber-reinforced composites, in particular for the production of rotor blade belts, a unidirectional non-crimp fabric made of glass fiber rovings is provided, the non-crimp fabric having a first stabilizing layer on the underside thereof and a second stabilizing layer on the upper side thereof, which layers are sewn together by pillar stitching.