Right-Angle Needle-Punching Mechanism for Angular Preforms

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Solution Overview

Problem

Existing needle-punching devices struggle to efficiently and high-quality standardize the preparation of angular preforms, such as square carbon/carbon sagger, due to their inability to perform needle punching on non-rounded corners, leading to low structural strength and product quality issues.

Innovation Solution

A right-angle needle-punching mechanism and device with a first and second right-angle needle-punching assembly, position adjusting assembly, and angle adjustment assembly, allowing simultaneous needle punching on both sides of the preform's right-angle parts, ensuring uniform density and strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If existing needle-punching devices are used for angular preforms, then the device structure is simple, but the manufacturing precision and structural strength at right-angle locations deteriorate

Engineering Contradiction:

Improveneedle punching quality at right-angle locationsVSAvoidneedle-punching mechanism structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The needle-punching mechanism is divided into multiple independent needle-punching assemblies (first right-angle needle-punching assembly, second right-angle needle-punching assembly, etc.), each responsible for specific regions of the preform. This segmentation allows precise control of needle punching at right-angle locations while maintaining overall device functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces angular adjustment capability to the needle-punching assemblies, enabling them to operate at specific angles (e.g., 45 degrees) relative to the preform surfaces. This angular dimension allows the needles to effectively reach and punch right-angle locations that conventional perpendicular assemblies cannot access.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If manual needle punching is used for square preforms, then the equipment investment is low, but the productivity and operational standardization deteriorate

Engineering Contradiction:

Improveneedle punching efficiencyVSAvoidneedle-punching device structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The needle-punching device is designed with multiple adjustable assemblies that can handle various preform shapes and sizes through parameter adjustment rather than requiring completely different equipment. The position and angle adjustments enable one device to perform multiple functions across different production scenarios.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The device incorporates dynamic adjustment mechanisms that allow the needle-punching assemblies to change their positions and angles during operation. This dynamic capability enables standardized automated needle punching for square preforms while maintaining adaptability for other geometries, thereby improving productivity without excessive complexity.

Inventive Principle:

Principle #15Dynamics

3Strength

If splicing method is used for carbon/carbon sagger, then the manufacturing complexity is low, but the structural strength and reliability deteriorate

Engineering Contradiction:

Improvestructural strength of carbon/carbon saggerVSAvoidpreform preparation process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The device performs preliminary needle punching actions that densely pack and interlace fibers throughout the entire preform volume, including critical right-angle locations, before the actual molding and carbonization processes. This preliminary fiber arrangement ensures uniform density and strong interlaminar bonding throughout the final product.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The needle-punching assemblies are specifically configured to provide enhanced local quality at right-angle locations through targeted fiber introduction and densification. The angular adjustment and positioned assemblies ensure that these critical regions receive appropriate needle punching treatment, creating locally optimized fiber structures that prevent future structural weaknesses.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12460331B1Right-angle needle-punching mechanisms and needle-punching devices

Publication Date: 2025.11.04 SHANGHAI QI JIE CARBON MATERIALS

AI summary

A right-angle needle-punching mechanism and a needle-punching device are provided. The right-angle needle-punching mechanism includes a first right-angle needle-punching assembly and a second right-angle needle-punching assembly, a position adjusting assembly configured to drive the first right-angle needle-punching assembly and the second right-angle needle-punching assembly approach or move away from the preform, and an angle adjustment assembly configured to change needle-punching angles of the first right-angle needle-punching assembly and the second right-angle needle-punching assembly. The angle adjustment assembly, the first right-angle needle-punching assembly, and the second right-angle needle-punching assembly are arranged on the position adjusting assembly. The first right-angle needle-punching assembly includes a first right-angle needle plate, the second right-angle needle-punching assembly includes a second right-angle needle plate, and the first right-angle needle plate and the second right-angle needle plate perform needle punching on respective sides of the right-angle part of the preform.