Multilayer Forming of Continuous Fibers Around a Mandrel
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Solution Overview
Problem
Forming complex composite shapes with fiber-reinforced thermoplastic materials while maintaining desirable mechanical properties is challenging, as traditional methods result in structural compromise and inconsistency due to fiber redistribution during deformation.
Innovation Solution
A method involving the stacking of fiber-reinforced laminate plies, ultrasonic tacking, and infrared-assisted slip forming around a mandrel, followed by consolidation under pressure and heat, to maintain consistent fiber distribution and prevent structural reorientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional heating and deformation methods are used to form complex composite shapes, then the desired complex geometry can be achieved, but fiber redistribution occurs causing structural compromise and inconsistent mechanical properties
Solution Approach 1:
The fiber reinforcement is pre-aligned and positioned in the desired orientation before the forming process begins. The laminate structure is prepared with fibers already in their final intended configuration, preventing redistribution during subsequent deformation operations.
Solution Approach 2:
The composite structure is divided into distinct layers (plies) with specific fiber orientations. Each ply can be independently positioned and secured, allowing precise control over fiber distribution throughout the multi-layer structure during the forming process.
2Shape
If traditional heating and deformation methods are used to form complex composite shapes, then the desired complex geometry can be achieved, but structural integrity is compromised due to fiber reorientation
Solution Approach 1:
The fiber reinforcement is pre-aligned and positioned in the desired orientation before the forming process begins. The laminate structure is prepared with fibers already in their final intended configuration, preventing redistribution during subsequent deformation operations.
Solution Approach 2:
The patent employs controlled temperature and pressure parameters during the forming process. By carefully managing these parameters, the material becomes sufficiently pliable to form complex shapes while the pre-positioned fibers maintain their structural alignment and load-bearing capacity.
3Shape
If fiber-reinforced thermoplastic materials are heated to induce deformation, then complex shapes can be formed, but the mechanical properties deteriorate due to fiber redistribution
Solution Approach 1:
The fiber reinforcement is pre-aligned and positioned in the desired orientation before the forming process begins. The laminate structure is prepared with fibers already in their final intended configuration, preventing redistribution during subsequent deformation operations.
Solution Approach 2:
The patent employs a multi-stage process with controlled heating and cooling cycles. The material is heated to a pliable state only when needed for shaping, then rapidly cooled to lock in the fiber positions and mechanical properties, creating a dynamic process that maintains reliability.
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 method allows for the repeatable formation of complex shapes with enhanced mechanical properties and damping characteristics, ensuring consistent fiber-to-matrix distribution and improved structural integrity.
Implementation Method 1
ultrasonically tacking a first portion of the laminate plies together
Implementation Method 2
applying infrared to the second portion of the laminate plies
Implementation Method 3
consolidating the first and second portion
Implementation Method 4
consolidating the first and second portion
Data Source
AI summary
A composite structure includes a polymer material, and axial fibers and radial fibers arranged within the polymer material. The composite structure includes a body and a sidewall that defines a cylindrical lumen. The sidewall has a consistent fiber to polymer distribution relative to the body.