Net Shape Preform Manufacturing Using Multi-Axial Fiber Strips
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Solution Overview
Problem
The conventional method of manufacturing carbon/carbon (C/C) brake disks from preforms cut or die punched from long boards of needled Oxidized Pan Fiber (OPF) material results in significant waste and inefficiency, as it involves continuous fiber orientations across the majority of each surface, which are typically built separately or in-situ on a needle loom.
Innovation Solution
A method and apparatus for manufacturing needled preforms using multi-axial narrow strips oriented in the circumferential direction, where layers of unidirectional and bi-directional carbon fiber textiles are needled together with minimal tension, allowing for staggered fiber orientations and reduced waste by cutting continuous strips from wider fabrics, and using a circular needle loom with controlled fiber delivery to achieve a net shape preform with improved mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional methods use continuous fiber orientations across the majority of each surface built separately or in-situ on a needle loom, then the preform can be manufactured, but significant material waste occurs and manufacturing efficiency is reduced
Solution Approach 1:
The invention segments the continuous fiber material into narrow strips with specific orientations (circumferential, radial, and diagonal strips at various angles). These segmented strips are then woven together to form the preform, eliminating the need to cut from large continuous boards and significantly reducing material waste while improving manufacturing efficiency.
2Strength
If multi-axial narrow strips oriented in the circumferential direction are used, then mechanical strength is improved, but the device complexity increases
Solution Approach 1:
The invention merges multiple types of narrow strips (circumferential, radial, and diagonal strips at various angles) into a single woven fabric structure. This combination of different oriented strips provides enhanced mechanical strength in multiple directions while being manufactured as an integrated preform, avoiding the need for separate manufacturing steps.
Solution Approach 2:
The invention transitions from two-dimensional continuous fiber layers to a three-dimensional multi-axial woven structure by incorporating strips oriented in multiple directions (circumferential, radial, and diagonal at various angles). This dimensional complexity in fiber arrangement provides superior mechanical strength while the weaving process integrates these orientations efficiently.
3Ease of manufacture
If preforms are cut or die punched from long boards of needled OPF material, then the manufacturing process is simpler, but significant material waste and reduced efficiency occur
Solution Approach 1:
The invention performs preliminary action by weaving the multi-axial narrow strips into the final preform shape before carbonization. This net-shape weaving approach eliminates the need for subsequent cutting or die-punching operations, reducing material waste and improving efficiency while maintaining manufacturing simplicity through an integrated weaving process.
Data Source
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AI summary
A preform manufacturing apparatus comprising a supply of fiber strip (106, 111, 116, 121, 201, 206, 211, 216), a moveable positive fiber strip delivery mechanism (120) coupled between a desired lay down location and the supply of fiber strip (101) to positively deliver and orient the supply of fiber strip (101) to the desired lay down location, and an optional electronic unwinder (115) coupled to the supply of fiber strip (101) when more delicate textile strips are used to fabricate the net shape preform is described herein. The electronic unwinder (115) is configured to interact with the moveable positive fiber strip delivery mechanism (120).