Reinforced Cellular Material Fiber Insertion Mechanism
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Solution Overview
Problem
Existing methods for reinforcing cellular materials with fibres result in excessively large holes in the material, leading to insufficient mechanical characteristics, as the resin fills the voids instead of the fibres, which is inadequate for lightweight aircraft construction.
Innovation Solution
A system and method for manufacturing reinforced cellular materials where a semi-finished textile product is placed in a hook without creating holes simultaneously, allowing fibre bundles to be inserted through pre-existing holes, ensuring the fibres enhance mechanical characteristics rather than the resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fibres are incorporated through simultaneous needle penetration and thread pulling, then the cellular material can be reinforced, but excessively large holes are generated which are filled by resin instead of fibres, resulting in insufficient mechanical characteristics
Solution Approach 1:
The process is divided into two separate operations: first creating holes in the cellular material, then subsequently inserting fibres into these pre-formed holes. This segmentation allows precise control over hole dimensions and ensures fibres are properly positioned without creating excessive voids that would be filled by resin.
Solution Approach 2:
Holes are created in the cellular material before fibre insertion. This preliminary action allows the hole geometry to be optimized independently, ensuring the holes are precisely sized to accommodate fibres while minimizing void space that would otherwise be filled by resin, thereby improving mechanical characteristics.
2Strength
If sewing techniques are used to incorporate fibres, then mechanical reinforcement is achieved, but the weight of the structure increases considerably
Solution Approach 1:
Fibres are inserted only at specific locations where mechanical reinforcement is needed, rather than uniformly throughout the entire cellular material. This localized approach provides targeted strength enhancement while minimizing additional weight, allowing optimization of the strength-to-weight ratio for specific application requirements.
3Adaptability or versatility
If pin density and pin angle are varied locally, then mechanical characteristics can be tailored to specific applications, but the complexity of the manufacturing process increases
Solution Approach 1:
The manufacturing system incorporates variable parameters including adjustable pin density and pin angle that can be dynamically changed during the fibre insertion process. This allows the same equipment to produce different reinforcement patterns tailored to specific application requirements, achieving adaptability without requiring multiple specialized manufacturing systems.
Data Source
AI summary
The invention relates to a device for producing a reinforced foam material and for receiving a textile semifinished product in a hook. To this end, the device has a first subunit having a transport device and a second subunit having a receiving device. The transport device is designed to convey the textile semifinished product into the receiving device, and the first subunit and the second subunit are designed such that the textile semifinished product can be presented in defined length by a relative movement of the first subunit relative to the second subunit. Furthermore, the receiving device of the second subunit is set up such that the textile semifinished product can be placed in the hooks by a relative movement of the receiving device relative to the hook.