Monofilament Fabric for Fiber Composite Surface Preparation
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Solution Overview
Problem
The existing methods for preparing the surface of fiber composite components for adhesion or coating are inefficient, often resulting in damage to the components and unreliable adhesion due to the use of multifilament fabrics, which require excessive force for tear-off and leave residues, leading to complex quality assurance processes.
Innovation Solution
A method utilizing a monofilament fabric with individual filaments arranged as a tear-off fabric on a fiber preform, where the matrix material is hardened with the fabric, allowing for cohesive fracture and minimal damage, creating a high surface energy surface suitable for adhesion and coating, with the fabric being designed to have a significant proportion of open areas for enhanced surface texturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multifilament fabric is used as tear-off fabric, then surface coverage is improved, but fabric removal requires excessive force and causes damage to the fiber composite structure
Solution Approach 1:
The patent divides the fabric structure from multifilament to monofilament construction, where individual filaments are separated and distributed across the surface. This segmentation allows the fabric to cover the surface area effectively while reducing the concentration of binding forces, enabling easier removal without excessive force or damage to the underlying fiber composite structure.
Solution Approach 2:
The patent changes the physical parameters of the tear-off fabric by specifying monofilament construction with filament diameters of 5-50 μm and mesh opening sizes of 10-100 μm. These parameter changes optimize the fabric's ability to provide surface coverage while controlling the removal force required, preventing damage to the fiber composite laminate.
2Area of stationary object
If multifilament fabric is used as tear-off fabric, then surface coverage is improved, but residue remains on the surface requiring complex quality assurance
Solution Approach 1:
By using monofilament fabric instead of multifilament, the patent segments the fabric into individual, easily removable filaments. This segmentation ensures complete removal of the tear-off fabric from the surface, eliminating residue that would otherwise require complex quality assurance processes to detect and remove.
Solution Approach 2:
The monofilament tear-off fabric is designed as a disposable element that is easily removed and discarded after serving its purpose of creating surface energy and texture. Its simple monofilament construction allows for complete removal without leaving residues, making it a cost-effective solution that eliminates the need for additional quality assurance steps.
3Reliability
If adhesive primer is used to prepare the surface, then adhesion is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent incorporates surface preparation actions into the initial curing process of the fiber composite component. The monofilament fabric is applied and cured together with the matrix material, creating the required surface energy and texture during the primary manufacturing process rather than as a separate subsequent step, thereby simplifying the overall manufacturing process while maintaining adhesion reliability.
Solution Approach 2:
The patent merges the surface preparation function with the structural curing process. By curing the matrix material and the monofilament fabric simultaneously in a single curing cycle, the patent combines what would traditionally be separate operations (structural curing and surface preparation), eliminating the need for additional adhesive primer applications and reducing manufacturing process complexity.
4Reliability
If matrix material is removed to create adhesive surface, then adhesion is improved, but fiber composite structure is damaged
Solution Approach 1:
The monofilament fabric serves as an intermediary element between the matrix material and the subsequent adhesive or coating. During removal, it creates a cohesively fractured surface with high surface energy that enhances adhesion, while the monofilament structure itself prevents direct mechanical damage to the reinforcing fibers by distributing stresses and avoiding the need to remove matrix material that would expose and potentially damage the fiber structure.
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 reliable adhesion and coating by minimizing damage to the fiber composite structure, reducing residue, and enhancing surface energy, allowing for effective application of materials without compromising the integrity of the laminate.
Implementation Method 1
Curing is generally achieved by applying heat and, if necessary, pressure. Curing forces the load-bearing fibers of the fiber material into their predetermined direction, forming an integral load-bearing unit with the cured matrix material.
Implementation Method 2
the monofilament fabric that is bonded to the fiber preform is torn off, whereby the matrix material in the application area is cohesively fractured
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2
AI summary
The invention relates to a method for applying a material (30) to a fiber composite component within an application region (13) of the fiber composite component, the fiber composite component being produced from a fiber composite material having a fiber material (11) and a matrix material (12), the method comprising the following steps: - providing at least one monofilament woven fabric (20), in which a plurality of or all threads each consist of a single filament, - arranging the at least one monofilament woven fabric (20) on a fiber preform (10) in the application region (13), which fiber preform is formed from the fiber material (11) of the fiber composite material, - curing, in a common process step, the matrix material (12) of the fiber composite material, which matrix material embeds the fibers material (11) of the fiber preform (10), and a matrix material (12) embedding the monofilament woven fabric (20), thereafter the matrix material (12) of the fiber preform (10) and the matrix material (12) of the monofilament woven fabric (20) being at least partially cured, - tearing off the monofilament woven fabric (20) integrally bonded to the fiber preform (10), and - applying the material (30) in the application region (13) after the monofilament woven fabric (20) has been torn off.