Multi-Needle Machine Repeating Unit for Reinforced Materials
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Solution Overview
Problem
Existing methods for reinforcing foam materials result in large puncture holes due to the size of the needle, leading to increased weight after resin infiltration, as the hole area not filled with fibers is filled with resin, which is inefficient for producing lightweight, high-strength composite materials, especially for large-format structural components like aircraft and wind turbine blades.
Innovation Solution
A multi-needle machine with a repetition unit that arranges textile semi-finished products along a periodically uneven path, using a combination of sliders and pins to guide the fibers into a zigzag or trapezoidal shape, allowing the needles to penetrate the material and pull the fibers through, reducing the hole size and increasing the fiber content within the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a needle is used to pierce the foam and insert the thread, then the thread can be incorporated into the foam material, but the puncture hole diameter becomes large compared to the thread diameter, leading to increased weight after resin infiltration
Solution Approach 1:
The invention changes the critical parameter of hole diameter by replacing the needle-based insertion method with a hook-based method. The hook has a significantly smaller diameter than the needle, which directly reduces the hole size created during fiber insertion. This parameter change allows the hole to be filled more efficiently with fibers rather than resin, thereby reducing the overall component weight while maintaining mechanical reinforcement.
Solution Approach 2:
The invention substitutes the mechanical needle piercing system with a hook-based system that operates on different mechanical principles. Instead of forcing a needle through the foam and pulling thread through a large hole, the hook catches the fiber end and pulls it through a much smaller opening. This mechanical substitution enables more efficient fiber placement and reduces the void space that would otherwise be filled with heavy resin.
2Productivity
If a needle inserts the thread parallel to the needle length, then the thread can be inserted through the foam, but the hole area not filled with fibers is filled with resin, reducing production efficiency
Solution Approach 1:
The invention changes the hole diameter parameter from large (needle-sized) to small (hook-sized), which fundamentally alters the resin consumption. The smaller hole created by the hook allows fibers to fill the void space more effectively, reducing the amount of resin needed to fill gaps. This directly improves production efficiency by reducing material waste and potentially reducing infiltration time.
3Strength
If conventional sewing methods are used to reinforce foam materials, then fibers can be incorporated into the foam, but the process is time-consuming and not suitable for high-speed production of large-format components
Solution Approach 1:
The hook-based system enables a form of self-service where the fiber itself guides the insertion process. The hook catches the fiber end and the fiber pulls itself through the foam material along the desired path, eliminating the need for complex needle-and-thread mechanisms. This self-service mechanism significantly simplifies the reinforcement process and enables high-speed operation suitable for large-format components.
Data Source
Figure 1
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Figure 4~5
AI summary
The invention relates to the production of reinforced materials such as reinforced foam materials or reinforced textiles. A multi-needle machine (200) is provided which comprises a plurality of repeating units (100) arranged in series that can move pushers (1) and pins (5) along a circuit towards and past one another in order for the textile semi-finished product (2) to be stretched out. This allows components with curved surfaces to be reinforced.