Multi-Needle Machine for Reinforced Materials
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Solution Overview
Problem
Existing methods for reinforcing cellular materials and textiles in sandwich constructions result in large holes due to needle penetration, leading to increased weight after resin infiltration, as the hole diameter is often larger than the incorporated thread, which is inefficient and weight-intensive.
Innovation Solution
A method using a multi-needle machine to arrange semi-finished textiles products in a non-linear manner, such as zigzag or wave-like patterns, on the rear surface of the material, allowing needles to penetrate and draw the textiles into the material efficiently, reducing hole size and increasing production speed by using hooks, rollers, or pegs for non-linear arrangement and guiding the textiles into the holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a needle penetrates the cellular material to incorporate thread, then the thread can be integrated into the material for reinforcement, but the hole diameter becomes relatively large compared to the thread diameter, increasing weight after resin infiltration
Solution Approach 1:
The semi-finished textiles product is arranged in a non-linear manner (zigzag or wave-like pattern) on the rear surface of the material before needle penetration occurs. This preliminary arrangement ensures that when needles penetrate and draw the thread through, the thread is already positioned to minimize hole size while maintaining reinforcement effectiveness.
Solution Approach 2:
The thread is arranged in a non-linear, curved pattern (zigzag or wave-like) rather than a straight line. This curvature allows the thread to be drawn through the material more efficiently by the needles, reducing the diameter of the holes created during penetration while still achieving adequate reinforcement coverage.
2Productivity
If traditional sewing methods are used with linear thread arrangement, then the process is simple to implement, but the production speed is slow and hole diameter is large
Solution Approach 1:
The semi-finished textiles product is pre-arranged in a non-linear manner on the rear surface of the material before the needle penetration process begins. This preliminary arrangement enables faster production by eliminating the need for complex real-time thread manipulation during needle movement, while still achieving reduced hole diameters and improved reinforcement efficiency.
Data Source
AI summary
This relates to the manufacturing of reinforced materials, such as reinforced cellular materials or reinforced textiles, for example. Reinforcement is achieved by including a textile semi-finished product into the material to be reinforced, by providing the semi-finished product at the rear side of the material in a zigzag or wave-like manner and then pulling the semi-finished product through the material by a plurality of needles. Thus, the manufacturing process may be performed in a time saving manner.