Hollow Fiber Composite Support Production via Soluble Core
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Solution Overview
Problem
Existing methods for producing hollow fibre composite components face challenges with limited mechanical stability, particularly in complex geometries and under high tensile/compressive forces, and are often time-consuming or unsuitable for thick-walled components.
Innovation Solution
A method involving a moulded body with a soluble plastic matrix made of polyvinyl alcohol (PVA) and a vacuum-assisted process to deposit and consolidate reinforcing fibres, allowing for the production of thick-walled, complex geometries with high fibre volume content and automated processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If permanent cores are used for complex geometries with undercuts and curvatures, then the core can represent complex geometries, but the core cannot be removed and becomes a lost core
Solution Approach 1:
The invention extracts the core material from the final component by using a soluble plastic matrix that can be dissolved after fibre deposition. The core is taken out through chemical dissolution rather than mechanical removal, enabling complex geometries to be represented while avoiding the lost core problem.
Solution Approach 2:
The invention changes the chemical parameter of the core material by using a soluble plastic matrix (such as PVA) that can transition from a solid state during fibre deposition to a dissolved state after processing. This parameter change allows the core to serve its function during manufacturing and then be easily removed afterward.
2Ease of operation
If lost cores made of wax are used, then the core can be removed after production, but the method is time-consuming and the wax has limited tensile and compressive strength
Solution Approach 1:
The invention replaces the mechanical melting and removal process of wax cores with a chemical dissolution process. The soluble plastic matrix is dissolved using appropriate solvents, which is faster and more efficient than waiting for wax to melt and be removed, significantly reducing the loss of time.
3Ease of operation
If cores made of water-soluble materials are used, then the core can be washed out, but the core has limited tensile and compressive strength for high force applications
Solution Approach 1:
The invention uses composite materials for the core construction, combining soluble plastic matrix with reinforcing fibres to create a core that has both sufficient mechanical strength during high-force fibre deposition and the ability to be washed out afterward. The composite structure provides the needed strength while maintaining removability.
4Stability of the object's composition
If foamed plastic cores are used, then the core remains in the component after fibre deposition, but the foamed plastic has only limited mechanical stability
Solution Approach 1:
The invention changes the parameter of core stability by using a soluble plastic matrix that maintains structural integrity during fibre deposition but can be completely removed afterward. This resolves the contradiction by providing temporary stability during manufacturing while enabling complete removal for final component performance.
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
Enables the production of stable, thick-walled hollow supports with complex geometries and high fibre volume content, suitable for applications under high forces, while simplifying the production process and allowing for automated manufacturing.
Implementation Method 1
a moulded body, formed as a hollow body, from a fibre composite material comprising reinforcing fibres and a soluble plastic matrix made of a matrix material soluble using a solvent
Implementation Method 2
arranging a vacuum setup comprising at least one, preferably several, film-like layers, or a pressure hose, on the outer surface of the moulded body
Data Source
AI summary
The application relates to a method for producing a hollow support from a fiber composite material, to a core designed as a hollow body, to the use of said core, and to the use of said hollow support made from fiber composite material.