Precision Tow Impregnation System for AFP Tolerance
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Solution Overview
Problem
Current Pre-impregnated Fiber Tow manufacturing machines lack the necessary dimensional accuracy for Automated Fiber Placement (AFP) and Automated Tape Laying (ATL) machines, requiring multiple costly steps to achieve the required tolerances, which doubles the material cost.
Innovation Solution
A single-process machine with opposing rollers and a nozzle system that forms a shaping space to precision-shape hot melt coated fibers, followed by instantaneous cooling to lock in the shape, allowing for precise control of fiber thickness and width, achieving dimensional accuracy within ±0.005 inches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-process Pre-impregnated Fiber Tow manufacturing machine is used, then the manufacturing cost is reduced, but the dimensional precision deteriorates (tolerance greater than .01 inches)
Solution Approach 1:
The shaping process is divided into distinct zones: a shaping zone with opposing rollers that form the initial geometry, and a cooling zone that sets the dimensions. This segmentation allows each zone to be optimized for its specific function, achieving both cost-effectiveness and precision in a single-pass process.
Solution Approach 2:
The patent controls the temperature of the resin and the cooling rate to precisely control the dimensional properties of the impregnated tow. By adjusting these parameters, the system achieves dimensional precision within ±.005 inches while maintaining a single-process manufacturing approach.
2Manufacturing precision
If master rolls are manufactured and then slit to required dimensions, then the dimensional precision is improved, but the device complexity increases (multiple steps required)
Solution Approach 1:
The patent combines multiple operations—resin impregnation, shaping, and cooling—into a single integrated process. The fiber tow passes through opposing rollers that simultaneously impregnate with resin and shape to the final dimensions, eliminating the need for separate slitting and rewinding operations.
Solution Approach 2:
The opposing rollers serve multiple functions: they guide the fiber tow, apply resin coating, and shape the tow to precise dimensions in one component assembly. This multi-functionality reduces the number of separate devices needed while maintaining precision.
3Manufacturing precision
If hot melt coated fiber is shaped through opposing rollers, then the manufacturing precision is improved, but the use of energy increases (cooling requirement)
Solution Approach 1:
The patent utilizes the phase transition of the hot melt resin from liquid to solid as it passes through the cooling zone. This phase change locks in the shaped dimensions without requiring excessive cooling energy, as the resin naturally solidifies at the transition point.
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
Enables the efficient, cost-effective production of dimensionally precise Unidirectional Shaped Tow with specifications suitable for AFP and ATL machines, reducing material costs and simplifying the manufacturing process while maintaining high tolerance requirements.
Implementation Method 1
Hot melt coated fiber is pulled through the shaping space and then instantaneously cooled to lock in the shape
Data Source
AI summary
A simple, cost effective Precision Shaped Tow Manufacturing system can produce high tolerance, dimensionally accurate, ready to use, Unidirectional Resin Impregnated Fiber Tow, Shaped Tow, in one procedure by a single machine that is precise enough to support Automatic Fiber Placement, AFP and Automatic Tape Laying specifications, ATL. The tow shaping system may include a Rotating Forming System, a Static Forming System, or both. A flash cooling chiller is provided to instantaneously set the tow to lock in the shape with a high tolerance.