Textile Preform Manufacturing via Hot Gas Flow Circulation
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Solution Overview
Problem
The manufacturing process of textile preforms from continuous fibres is inefficient due to lengthy temperature raising and lowering phases, impacting manufacturing time in the production of composite materials for aeronautics and automobiles.
Innovation Solution
A process involving a hot gas flow through the matrix and punch to heat and cool the fibrous array, with sliding layers of lower friction interposed between fibrous layers to reduce friction forces and facilitate faster processing, using a tooling system with multiperforated portions for gas passage and a gas flow funnel for uniform heating and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heating methods (oven or heating elements in tooling) are used, then the fibrous array can be heated to melt resin, but the manufacturing time is excessively long due to lengthy temperature raising and lowering phases
Solution Approach 1:
The patent introduces a pneumatic system that circulates hot gas flow through the fibrous array via perforations in the punch and matrix. This forced convection method dramatically accelerates heating compared to conventional thermal conduction methods, reducing the temperature raising phase from hours to minutes while maintaining effective resin melting and bonding.
Solution Approach 2:
The patent changes the heating mechanism from passive thermal conduction to active forced convection by introducing pressurized hot gas flow. This parameter change in the heating method transforms the time-consuming process into an efficient operation, directly addressing the contradiction between heating effectiveness and manufacturing time.
2Ease of operation
If sliding layers with low friction coefficient are interposed between fibrous layers, then friction forces are reduced and processing is facilitated, but the structural complexity of the fibrous array increases
Solution Approach 1:
The patent introduces sliding layers as intermediary elements between adjacent fibrous layers. These layers have a lower friction coefficient than the fibrous materials themselves, reducing inter-layer friction during stamping operations. The sliding layers act as mediators that facilitate smooth relative movement while maintaining the overall structural integrity of the composite assembly.
3Productivity
If hot gas flow is circulated through the matrix, fibrous array and punch, then manufacturing time is significantly reduced, but the tooling complexity increases due to multiperforated portions and gas flow funnel
Solution Approach 1:
The patent segments the tooling structure by introducing multiperforated portions in both the punch and matrix. These perforations create multiple gas flow paths that distribute hot gas uniformly throughout the fibrous array. The segmentation allows efficient heat transfer while maintaining a relatively simple overall tooling design that can be manufactured with standard techniques.
Solution Approach 2:
The patent designs the multiperforated portions to serve multiple functions: they allow gas flow for heating, provide structural support for the fibrous array, and enable uniform distribution of thermal energy. This multi-functionality reduces the need for separate components, thereby limiting the increase in tooling complexity while achieving high productivity.
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 significantly reduces manufacturing time by employing forced convection heating and cooling, cutting down the time required for the textile preform production compared to conventional methods, while maintaining the quality and shape of the final composite material.
Implementation Method 1
The use of this technique by forced convection considerably cuts down the manufacturing time of the textile preform
Implementation Method 2
The process comprises, after the step for heating, a step for cooling the fibrous array performed by having a flow of cooling gas circulate through the matrix, the fibrous array and the punch
Data Source
AI summary
The invention relates to a process for manufacturing a textile preform from a fibrous array with continuous fibres, the process comprising a step for heating of the fibrous array between a matrix and a punch to stiffen this fibrous array. To cut down processing time, the heating step is performed by having a hot gas flow circulate through the matrix, the fibrous array and the punch.