Impregnation plant and method for impregnating a textile sheet material for composite components
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Solution Overview
Problem
Existing impregnation systems for textile fabrics in composite components face challenges in achieving uniform pressure distribution, leading to uneven impregnation of the matrix material, particularly at high production speeds, resulting in incomplete penetration and poor quality prepregs.
Innovation Solution
The impregnation system employs adjustable endless belt loops with deflection rollers that can be adjusted in the y-direction to apply consistent pressure perpendicular to the fabric, ensuring even penetration of the matrix material, and allows for independent adjustment of additional rollers to vary pressure and angle of wrap, ensuring uniform impregnation across the fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high production speeds are used in traditional roller impregnation systems, then productivity increases, but pressure distribution becomes uneven leading to incomplete matrix penetration
Solution Approach 1:
The impregnation system is divided into multiple independent belt loops (first and second belt loops) that can be adjusted independently. Each belt loop applies pressure to specific zones of the textile fabric, allowing segmented pressure application that maintains uniformity across the entire fabric width even at high production speeds.
Solution Approach 2:
The deflection rollers are made adjustable in the y-direction, allowing dynamic adaptation of the belt loop geometry and pressure application points. This dynamic adjustability enables the system to maintain optimal pressure distribution across different production speeds and fabric types.
2Manufacturing precision
If traditional roller systems apply line pressure to impregnate textile fabric, then impregnation occurs, but pressure is not uniformly distributed across the fabric surface
Solution Approach 1:
The system uses flexible endless belts forming closed loops that conform to the fabric surface and distribute pressure uniformly. The belt flexibility allows continuous contact with the fabric across the entire width, replacing the line contact of rigid rollers with surface contact that ensures even pressure distribution.
Solution Approach 2:
The pressure application is transitioned from a one-dimensional line contact (roller-to-fabric) to a two-dimensional surface contact (belt-to-fabric). This dimensional change allows pressure to be distributed across the entire fabric width simultaneously, achieving uniform impregnation.
3Force
If multiple pairs of rollers are arranged in close succession to maintain compressive force, then continuous pressure is applied, but pressure drops significantly between roller pairs
Solution Approach 1:
The endless belt loops provide continuous pressure application along the entire path of the fabric through the impregnation zone. Unlike discrete rollers that create intermittent pressure, the continuous belts maintain constant compressive force on the fabric throughout the impregnation process, ensuring complete matrix penetration without pressure gaps.
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 ensures continuous and uniform pressure application, resulting in high-quality prepregs with improved mechanical properties and increased flexibility, as the matrix penetrates evenly throughout the textile fabric, enhancing the reliability and isotropy of the composite components.
Implementation Method 1
adjustable endless belt loops with deflection rollers that can be adjusted in the y-direction to apply consistent pressure perpendicular to the fabric
Implementation Method 2
the materials to be impregnated are continuously bonded or impregnated via roller systems under pressure
Data Source
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AI summary
An impregnation system and a method for impregnating a textile surface for composite components are described. A matrix 2 can be applied to a textile surface 1 such that the latter is at least partially and/or at least on one side penetrated by the matrix 2. The impregnation system comprises a first and a second continuous belt 1, each configured as a belt loop. The textile surface 1 is guided between the first 4 and the second belt loop 5 at the mutually facing surfaces 6 of the belt loops and can be impregnated there. The deflection rollers 7 are provided in the respective belt loops 4 and 5 of the respective continuous belts at the deflection points, with at least one roller in each loop being adjustable in the direction of the mutually facing surfaces 6 of the belt loops 4 and 5.By adjusting the rollers 8 in the y-direction, the wrapping angle and thus the pressure exerted on the textile surface during impregnation is controlled.