Laser-Welded Thread Winding for Stronger Composite Components
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Solution Overview
Problem
Current manual processes for manufacturing composite components, such as aerospace and high-performance car parts, are slow, inconsistent, and prone to weaknesses due to gaps and linear attachment patterns, which compromise the strength and reliability of the final product.
Innovation Solution
A computer-controlled method using a laser to automate the winding of thread-like materials around a mandrel, applying the laser at predetermined non-linear points to attach adjacent turns and fill gaps with powdered material, enhancing stability and strength by orienting layers differently and using HIPing for final treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processes are used to wrap substrate sheets and apply resin, then flexibility and adaptability are maintained, but production speed is slow and consistency is poor
Solution Approach 1:
The patent replaces manual mechanical wrapping and resin application with an automated laser-based system. The laser welds adjacent turns of the substrate sheet directly, eliminating the need for manual resin application and subsequent curing processes, thereby dramatically increasing production speed and consistency
Solution Approach 2:
The laser beam induces localized melting (phase transition) of the substrate material at adjacent turns, creating strong bonds without requiring manual resin application. This phase transition approach enables automated joining while maintaining material integrity
2Reliability
If linear attachment patterns are used to join turns, then the process is simple, but weaknesses are created in the component
Solution Approach 1:
The patent distributes laser attachment points along a non-linear, curved path around the mandrel rather than using straight linear patterns. This curved distribution of attachment points creates more uniform stress distribution and eliminates the weaknesses associated with linear attachment patterns
Solution Approach 2:
The laser applies localized heating and welding at specific distributed points along the non-linear path, creating locally optimized bond strength where needed most, rather than uniform attachment throughout. This allows for targeted reinforcement at critical stress points
3Strength
If gaps are left between adjacent threads, then material usage is reduced, but component strength is compromised
Solution Approach 1:
The laser beam melts (phase transition) the edges of adjacent substrate turns, creating a molten zone that fills gaps and creates strong metallurgical bonds. This localized melting eliminates gaps between threads while using minimal material, as the bonding is achieved through fusion rather than adding filler material
Solution Approach 2:
The laser process changes the physical state (parameter) of the substrate material at the bonding interface, transforming it from solid to molten and back to solid, creating a strong bond that fills gaps without requiring additional material volume
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 method enables rapid, consistent, and strong component manufacturing by preventing lateral movement and filling gaps, resulting in improved rigidity and reduced weaknesses in the final product.
Implementation Method 1
applying a laser beam to cause melting of the powder
Implementation Method 2
cause melting of the powder
Implementation Method 3
employing one or more lasers... to attach adjacent turns
Data Source
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AI summary
A computer-controlled method of component manufacture is disclosed, comprising winding a thread of material around a shaping element to form a first layer formed of adjacent turns of said thread This is repeated to form a second layer of adjacent turns of said thread on top of the first layer. A laser beam is then applied between adjacent turns of each layer to attach them at predetermined points.