Large Fiber Tow Segmentation for Composite Fabric Quality
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Solution Overview
Problem
The use of large fiber tows in composite structures results in inferior fabric quality due to large interstitial spaces and microcracking, while small fiber tows are more expensive to produce, making them less economical for widespread use.
Innovation Solution
A method involving the spreading and melt-bonding of large fiber tows to form wide, flat, unidirectional fabrics, which are then slit into narrow tows, reducing interstitial spaces and improving fabric quality without increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large fiber tows are used to reduce manufacturing cost, then productivity increases, but fabric quality deteriorates due to large interstitial spaces and microcracking
Solution Approach 1:
The patent applies segmentation by dividing a large fiber tow into multiple smaller sub-tows or strands. This is achieved through mechanical processes such as opening, randomizing, and dividing the large tow into controlled smaller bundles. The segmentation maintains the cost advantage of using large tows while achieving the fabric quality characteristics of smaller tows by reducing interstitial spaces and preventing microcracking through more uniform fiber distribution.
Solution Approach 2:
The patent transforms the fiber tow from a three-dimensional bundled structure into a two-dimensional mat or web structure before re-bundling into smaller tows. This dimensional change allows for better fiber separation, randomization, and uniform distribution. The mat formation process enables the fibers to be laid flat and evenly distributed, which when re-bundled into smaller tows, produces superior fabric quality with reduced interstitial spaces compared to直接使用 large tows.
2Manufacturing precision
If small fiber tows are used to improve fabric quality, then manufacturing precision improves, but productivity decreases due to reduced machine capacity utilization
Solution Approach 1:
The patent applies preliminary action by pre-processing large fiber tows into mats or webs with controlled fiber distribution, randomization, and opening before dividing them into smaller tows. This preliminary mat formation and fiber randomization ensures that when the tows are later used in fabric production, they exhibit the quality characteristics of small tows. The preliminary processing eliminates the need to start with already-separated small tows, thereby maintaining manufacturing efficiency while achieving high fabric quality.
3Ease of manufacture
If large fiber tows are used in braids, then manufacturing cost decreases, but reliability deteriorates due to resin-rich pockets and microcracks
Solution Approach 1:
The patent applies segmentation by dividing large fiber tows into multiple smaller sub-tows before braid fabrication. This segmentation creates a more uniform fiber distribution within the braid structure, preventing the formation of large resin-rich pockets that occur when using intact large tows. The smaller sub-tows allow resin to distribute more evenly throughout the braid, eliminating concentration points that lead to microcracks and improving overall structural reliability while maintaining the cost advantages of starting with large tows.
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 allows for the production of low-cost, high-quality composite structures with reduced microcracking and improved performance by utilizing narrow fiber tows, which maintain the quality of small fiber tow fabrics at a lower expense.
Implementation Method 1
subjecting the flattened fabric to a melt-bonding process while held under tension to maintain the flattened configuration
Data Source
AI summary
A method for using a tow incorporating a large number of fibers to form a composite part that has the quality of parts made with tows incorporating a small number of fibers is described. The method includes spreading the tows incorporating a large number of fibers to form a relatively wide, flat, and continuous, unidirectional fabric, holding the fabric under tension to maintain the orientation and flatness, subjecting the flattened fabric to melt-bonding while held under tension to maintain the flattened configuration, and slicing the melt-bonded, unidirectional fabric into a plurality of narrow fiber tows and subsequently using these to produce braided, woven, and other fabric forms.