Oblique Jet Deflection for Discontinuous Fiber Alignment
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Solution Overview
Problem
Existing methods for aligning discontinuous fibers in composite manufacturing face challenges in achieving high performance ductile materials with reduced manufacturing time without compromising fibre alignment, leading to limitations in reliability, safety, and design requirements.
Innovation Solution
An apparatus and method involving a nozzle directing a jet of liquid with fibers at an oblique angle onto an alignment surface, which deflects into a channel, allowing fibers to move and align further within the channel, utilizing a low-viscosity liquid to enhance alignment efficiency and reduce processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a high-viscous working fluid is used to align fibers, then fiber alignment level is improved, but manufacturing time increases and cost effectiveness decreases
Solution Approach 1:
The patent changes the viscosity parameter of the working fluid from high (glycerine) to low (water-based), and compensates by adjusting flow velocity and channel geometry to achieve effective fiber alignment without the slowdown associated with high-viscosity fluids
Solution Approach 2:
The patent uses hydraulic flow of low-viscosity water-based fluid through controlled channels to transport and align fibers, replacing the high-viscosity fluid mechanism with a hydraulic system that enables faster processing while maintaining alignment quality
2Productivity
If processing time is reduced to improve cost effectiveness, then manufacturing speed increases, but fiber alignment levels decrease
Solution Approach 1:
The patent introduces dynamic control of flow velocity through the channel system, adjusting the speed of water-based fluid flow to optimize both processing time and fiber alignment, allowing fast processing without sacrificing alignment quality
Solution Approach 2:
The patent changes multiple parameters simultaneously - using low-viscosity fluid, increasing flow velocity, and optimizing channel dimensions - to achieve fast processing speeds while maintaining high fiber alignment levels
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
The method achieves improved fiber alignment, enabling the production of high-performance ductile composite materials with faster fabrication times, increased reliability, and reduced design and maintenance needs, while maintaining high alignment levels.
Implementation Method 1
directs a jet of liquid containing discontinuous fibres onto the alignment surface so that the jet of liquid is deflected by the alignment surface into the channel, and wherein the apparatus is further arranged such that in use the fibres move along the channel
Data Source
Figure 1~2b
Figure 3
Figure 4~5b
AI summary
A method of manufacturing a fibre preform with aligned discontinuous fibres. A jet of liquid containing discontinuous fibres is directed onto an alignment surface from a nozzle so that the jet meets the alignment surface at an oblique angle and is deflected by the alignment surface into a channel between an opposed pair of channel surfaces. The fibres move along the channel after the jet has been deflected into the channel by the alignment surface. The liquid is removed from the fibres to provide the fibre preform which may optionally be impregnated with matrix to form a composite tape. At least some of the fibres have a length greater than a spacing between the channel surfaces.