Multi-Mandrel Braiding Assembly for Continuous Preform Production

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Solution Overview

Problem

Braiding processes for producing fibrous ceramic preforms are costly due to scrap material generation and require significant manual intervention, leading to inefficiencies in producing high volumes of preforms.

Innovation Solution

A multi-mandrel assembly system for braiding, comprising a mandrel assembly with a lead-in extension, end extension, and removably connected mandrels and transition pieces, allows for continuous braiding and automated processing, reducing waste and manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional single-mandrel braiding is used, then manual intervention is required for each preform, but productivity is low and scrap material is generated

Engineering Contradiction:

Improveproduction volume of preformsVSAvoidscrap material

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

Multiple individual mandrels are merged into a single integrated mandrel assembly that can produce multiple preform segments simultaneously. The mandrel assembly includes multiple mandrels arranged in a specific configuration, allowing continuous fiber reinforcement to be braided around all mandrels in one continuous operation, thereby increasing productivity while reducing scrap material from lead-in/lead-out regions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mandrel assembly serves multiple functions simultaneously: it acts as the structural support for braiding, the template for multiple preform geometries, and the fixture for subsequent processing steps. The assembly can be configured for different preform types and can accommodate various fiber reinforcement patterns, making it a universal tool for producing different CMC parts

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If traditional braiding process is used, then scrap material is generated, but manufacturing precision is compromised

Engineering Contradiction:

Improvepreform qualityVSAvoidscrap material

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

By combining multiple mandrels into one assembly with continuous fiber reinforcement passing through all mandrels, the system eliminates the need for separate lead-in and lead-out regions for each individual preform. The fiber reinforcement continues continuously through the entire mandrel assembly, preventing the generation of scrap material while maintaining precise control over each preform's geometry and fiber distribution

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If manual braiding process is used, then flexibility is maintained, but loss of time increases

Engineering Contradiction:

Improveproduction speedVSAvoidprocessing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system enables continuous braiding operation where fiber reinforcement is wound continuously around multiple mandrels in the mandrel assembly without interruption. This continuous action eliminates the time losses associated with stopping and starting braiding for each individual preform, significantly reducing total processing time while maintaining production flexibility

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The mandrel assembly is pre-configured with multiple mandrels in the desired geometric arrangement before braiding begins. This preliminary setup allows the braiding process to proceed immediately in a continuous manner without requiring intermediate adjustments or reconfigurations during production, thereby reducing loss of time

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If multiple individual mandrels are used, then each preform can be customized, but device complexity increases

Engineering Contradiction:

Improvepreform customizationVSAvoidmandrel assembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mandrel assembly is segmented into multiple individual mandrels that can be independently configured for different preform geometries and fiber reinforcement patterns. Each mandrel within the assembly can be customized for specific preform requirements while still being part of the integrated assembly, allowing versatility without excessive overall complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mandrel assembly is designed as a universal fixture that can accommodate various preform types and configurations. The standardized structure of the assembly allows for easy reconfiguration and adaptation to different production requirements, maintaining adaptability while managing device complexity through modular design

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12565451B2Multi-mandrel braiding process

Publication Date: 2026.03.03 RTX CORP

AI summary

A system for forming multiple braided preform segments includes a mandrel assembly disposed along a mandrel axis, a radial braider for winding fibers onto the mandrel assembly to form a continuous braided article, an applicator for applying a polymer binder to the braided article while mounted on the mandrel assembly, and a debulking tool for debulking the braided article while mounted on the mandrel assembly. The mandrel assembly includes a lead-in extension defining a first end, an end extension defining a second end, and a plurality of mandrels removably connected to a plurality of transition pieces and disposed axially between the lead-in extension and the end extension.