Hybrid Braided Composite Structure for Built-In Static Dissipation
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Solution Overview
Problem
Existing methods for fabricating fiber-reinforced composite parts, such as filament-wound fiberglass tubes, are limited by the number and type of interlacements between fibers, which restricts versatility and require additional steps like adhering copper mesh for static charge dissipation, slowing down production.
Innovation Solution
A method and system for braiding composite parts using both fiberglass and carbon fibers, where carbon fibers are integrated to conduct static charges and are woven with fiberglass without separate adhesion, enhancing strength and maintaining production speed by integrating conductive and insulating fibers within the braiding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper mesh is adhered to fiberglass tubes for static charge dissipation, then static charge dissipation capability is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent combines the structural fiberglass material with conductive carbon fibers into a single hybrid composite material. The carbon fibers are integrated during the braiding process itself, merging the structural function (fiberglass) and the static dissipation function (carbon fibers) into one unified component, eliminating the need for separate copper mesh attachment steps
Solution Approach 2:
The patent uses a composite material system combining fiberglass and carbon fibers in a hybrid braid. This composite approach allows both materials to work together within the same structure, with fiberglass contributing to mechanical strength and carbon fibers contributing to electrical conductivity for static dissipation
2Reliability
If additional static dissipation elements are adhered to composite parts, then static charge dissipation is improved, but production speed decreases
Solution Approach 1:
The conductive carbon fibers are incorporated into the hybrid composite structure during the initial braiding process, before the part is completed. This preliminary integration of the static dissipation function eliminates the need for subsequent attachment operations, maintaining continuous production flow and speed
Solution Approach 2:
The braiding process simultaneously creates the structural form and integrates the conductive elements in one continuous operation. The structural fiberglass and conductive carbon fibers are woven together in real-time during braiding, combining multiple functions into a single manufacturing step rather than sequential steps
3Productivity
If filament winding is used for composite fabrication, then production efficiency is maintained, but versatility in fiber interlacements is limited
Solution Approach 1:
The braiding process uses dynamic, moving heads that can independently control multiple fiber tows in three-dimensional space. This allows complex interlacing patterns and variable fiber orientations to be achieved during the braiding process itself, providing versatility without sacrificing production efficiency through continuous motion and real-time adjustment
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 eliminates the need for additional static dissipation elements, enhances structural strength, and maintains production speed by integrating conductive carbon fibers with fiberglass, allowing for efficient fabrication of hybrid composite parts.
Implementation Method 1
The carbon fibers, because they are conductive, are capable of dissipating static charges
Implementation Method 2
impregnated with the same resin (e.g., a thermoset or thermoplastic resin) for hardening
Data Source
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AI summary
Systems and methods are provided for fabricating a hybrid composite part. A method includes braiding a first set of fibers to form a weave having a closed cross-sectional shape, braiding a second set of fibers into the weave that are chemically distinct from the first set of fibers, impregnating the weave with a resin, and hardening the resin within the weave to form a hybrid composite part.