Low-Bulk Composite Fabric via Pre-Consolidated Tape Laying
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Solution Overview
Problem
Current methods for manufacturing composite materials using low-pressure molding processes often result in inconsistencies, such as undesired bulk and fiber dislocations, leading to suboptimal quality and weight issues in composite components.
Innovation Solution
A method involving the formation of a fiber layer and a porous bonding layer to create a unidirectional lay-up of fibers, which are then heated under pressure to form a composite tape with controlled gaps between fiber tows, allowing for the construction of composite fabrics with improved fiber alignment and reduced bulk, using a conveyor bed and tape-lay-down units to lay down layers at specific angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low-pressure molding processes are used to manufacture composite materials, then expensive autoclaves are avoided, but inconsistencies such as undesired bulk and fiber dislocations occur
Solution Approach 1:
The patent applies preliminary action by pre-consolidating fiber tows into a stable configuration before the low-pressure molding process. The fiber tows are arranged and secured in their desired orientation prior to molding, which prevents fiber dislocation during the subsequent low-pressure curing process. This pre-positioning ensures manufacturing precision is maintained even without autoclave-level pressure.
Solution Approach 2:
The patent changes the pressure parameter from high-pressure autoclave processing to low-pressure molding, while compensating for the reduced pressure control through other means such as pre-consolidation of fibers and optimized tooling design. This parameter change allows avoidance of expensive autoclaves while maintaining acceptable manufacturing precision through complementary process adjustments.
2Device complexity
If current composite fabric manufacturing methods are used, then production is simplified, but undesired bulk is created in the composite components
Solution Approach 1:
The patent changes the consolidation parameter by applying controlled pressure and heat during the molding process to reduce the bulk of the composite fabric. By optimizing these parameters, the process maintains simplicity while achieving the desired low-bulk outcome in the final component.
Solution Approach 2:
The patent applies preliminary consolidation to the fiber layers before final curing, which reduces bulk early in the process. This pre-consolidation step prevents excessive bulk formation while keeping the overall process simple and avoiding the need for complex multi-step operations.
3Manufacturing precision
If fiber tows are clamped down at different orientations to create fabric, then fiber alignment is achieved, but bulk is increased due to layer consolidation
Solution Approach 1:
The patent changes the consolidation parameters by applying controlled heat and pressure during the molding process to compress the multi-oriented fiber layers. This reduces the bulk that naturally occurs when fibers are arranged at different orientations, while preserving the alignment benefits of multi-directional fiber placement.
Solution Approach 2:
The patent uses a composite structure combining fibers oriented at different orientations within a resin matrix. This composite approach allows the fibers to provide strength in multiple directions while the resin matrix consolidates them into a compact structure with reduced bulk, maintaining both alignment benefits and volume efficiency.
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 minimizes inconsistencies and achieves a composite fabric with desired thickness and fiber configuration, enabling the production of composite components with enhanced mechanical performance and reduced weight, suitable for large-scale aircraft components without the need for expensive autoclaves.
Implementation Method 1
A unidirectional lay-up of fibers is formed. The unidirectional lay-up of fibers is heated under pressure to melt and bond the porous bonding layer to the fiber layer to fix a position of the fibers
Implementation Method 2
The unidirectional lay-up of fibers is heated under pressure to melt and bond the porous bonding layer to the fiber layer
Data Source
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Figure 3
Figure 5~6
AI summary
A method and apparatus for manufacturing a fabric. A fiber layer (400) and a porous bonding layer (402) are formed to form a unidirectional lay-up of fibers (404). The lay-up of fibers is heated under pressure to form a unidirectional composite tape (408) of desired thickness to substantially maintain the fibers in a desired configuration. The unidirectional composite tape is slit to a desired width, and the slit unidirectional composite tape is loaded into a multiaxial fabric machine. A first layer (414) is built from the composite tape in the multiaxial machine, and a second layer (416) is built from the composite tape on the first layer at a predetermined angle from the first layer in the multiaxial machine. The first and second layers are consolidated to form a composite fabric (418) in a continuous process.