Pull-Through Winding Fixture for Straight Fiber Layup
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional load bearing structures, such as iso-truss and iso-grid structures, struggle to maintain the alignment of fibers during the winding process, leading to reduced structural strength due to bends or crimps in the material, which can introduce points of failure.
Innovation Solution
A pull-through winding method and manufacturing fixture are employed to guide the layup of material, ensuring fibers are pulled and maintained as straight as possible during the winding and curing process, using guide flanges, support members, and guide pins to achieve consistent tension and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional winding methods are used, then the manufacturing process is simpler, but fiber alignment is poor leading to reduced structural strength
Solution Approach 1:
Guide flanges and guide pins are introduced as intermediary elements to mediate the winding process. The guide flanges with slots and the guide pins work together to constrain and guide the material, ensuring fibers remain aligned and straight during the winding process, thereby resolving the contradiction between manufacturing simplicity and fiber alignment precision
Solution Approach 2:
The manufacturing fixture is segmented into multiple functional components: guide flanges with slots, support members, and guide pins. This segmentation allows each component to perform a specific function in maintaining fiber alignment, with the guide flanges providing structural framework and the guide pins providing precise directional guidance for the material
2Manufacturing precision
If guide flanges with slots and guide pins are used, then fiber alignment is improved, but device complexity increases
Solution Approach 1:
The guide flanges serve multiple functions: they provide the structural framework of the fixture, contain slots that guide material placement, and work with guide pins to maintain fiber alignment. This multi-functionality reduces the need for separate components, thereby managing device complexity while achieving precise fiber alignment
3Strength
If material is pulled through slots with tension, then fiber straightness is maintained, but the winding process becomes more complex
Solution Approach 1:
The guide flanges and guide pins are designed to automatically maintain tension and alignment during the winding process. As material is wound through the slots and guided by the pins, the fixture itself provides the necessary constraints and guidance without requiring external intervention or complex control mechanisms, making the process self-regulating
Data Source
AI summary
Systems and methods are directed to a pull-through winding method, and a manufacturing fixture, or mandrel, that guides the layup of material in the pull-through winding method, for fabrication of a three-dimensional load bearing structure. These systems and methods allow fibers of material of the 3D load bearing structure to be pulled as straight as possible during winding, and maintained as straight as possible during curing, to take full advantage of properties associated with the fiber or filament-based materials used in these structures, including, for example, carbon fiber material. The manufacturing fixture includes a plurality of pull-through slots at end portions thereof, that provide for the pulling of the fiber-based material, and the application and maintenance of tension in the material that maintains the alignment of the fibers as the material is wound, cured and hardened.