Prepreg Tape Textile Structure for Composite Forming
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Solution Overview
Problem
Existing methods for manufacturing multi-curved structural components from fiber composite materials often result in wrinkle formation during the forming process, which compromises the mechanical strength and efficiency of the final product.
Innovation Solution
A semi-finished product comprising prepreg tapes with unidirectionally arranged reinforcing fibers embedded in a thermoplastic matrix material, combined with connecting strands of thermoplastic material, forms a textile sheet structure that allows for anisotropic deformation, preventing wrinkling by enabling the prepreg tapes to slide relative to each other. This structure eliminates the need for subsequent matrix infiltration and allows for efficient deposition and forming of complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mat-shaped semi-finished fiber products are stacked and shaped, then structural components can be produced, but wrinkle formation occurs during the forming process
Solution Approach 1:
The semi-finished product is divided into multiple prepreg tapes arranged in parallel, with each tape consisting of unidirectionally arranged reinforcing fibers embedded in thermoplastic matrix material. This segmentation allows each tape to slide independently relative to others during forming, preventing wrinkle formation while maintaining manufacturing feasibility
Solution Approach 2:
The connecting strands are designed to be detachable or slideable rather than rigidly fixed, allowing dynamic adjustment during the forming process. This enables the prepreg tapes to move relative to each other smoothly, preventing fiber buckling and wrinkle formation while still maintaining structural integrity
2Stability of the object's composition
If connecting strands are provided at all crossing points of prepreg tapes, then structural stability is improved, but wrinkle formation increases during deformation
Solution Approach 1:
Connecting strands are provided only at specific locations (e.g., at the ends of prepreg tapes or at spaced intervals) rather than at all crossing points. This local connection approach maintains sufficient structural stability while allowing relative sliding between tapes at uncrossed points, thereby preventing wrinkle formation during deformation
3Manufacturing precision
If prepreg tapes are rigidly fixed to prevent sliding, then wrinkle formation is reduced, but anisotropic deformation capability is limited
Solution Approach 1:
The connecting strands are designed with controlled flexibility or detachability, allowing the prepreg tapes to slide relative to each other in specific directions during forming operations. This dynamic connection system enables anisotropic deformation capability while maintaining sufficient structural stability, resolving the contradiction between fixed stability and deformation adaptability
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 solution significantly reduces wrinkle formation, enhancing the mechanical strength and ease of production of large, flat structural components with complex geometries, such as those used in aircraft construction, by allowing the prepreg tapes to slide and preventing fiber buckling during deformation.
Implementation Method 1
the textile structure allows the prepreg tapes to slide along each other, which prevents wrinkling during deformation
Data Source
AI summary
A semi-finished product for the manufacture of a structural component has a plurality of prepreg tapes, each having unidirectionally arranged reinforcing fibers embedded in a thermoplastic matrix material, and with a plurality of connecting strands containing a thermoplastic material. The prepreg tapes and the connecting strands are either joined to form a textile sheet structure or the prepreg tapes are arranged to form a multiaxial fabric, individual layers of the fabric being joined by the connecting strands. Further, a method for manufacturing a curved structural component from such a semi-finished product is described.