Self-Cleaning Needle Arrangement for Resin Clog Prevention
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Solution Overview
Problem
Existing through thickness reinforcement methods, such as needling, stitching, and tufting, face challenges with needle clogging due to resin infusion, compromising the reinforcement process in carbon/carbon composites, particularly in resin-infused fabrics, leading to compromised performance and increased maintenance costs.
Innovation Solution
A self-cleaning needle arrangement that incorporates a needle cleaning material, such as bristle brushes or rigid foam, which slides or rotates relative to the needle to clean the surface during or between reinforcement processes, reducing the need for frequent tool changes and maintaining process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If needles are used for through thickness reinforcement in resin-infused fabrics, then reinforcement effectiveness is improved, but needle clogging occurs leading to reduced reliability
Solution Approach 1:
The needle cleaning material is configured to automatically clean the needle surface during the needling process through self-service mechanism. The cleaning material contacts the needle as it moves through the fabric, removing resin buildup without requiring external intervention or manual cleaning between operations.
Solution Approach 2:
A needle cleaning material is introduced as an intermediary component between the needle and the resin-infused fabric. This cleaning material prevents direct contact between resin and needle surfaces, thereby preventing clogging while allowing the needling process to continue effectively.
2Reliability
If needles are cleaned manually between operations, then needle performance is maintained, but production time increases and productivity decreases
Solution Approach 1:
The cleaning mechanism operates automatically during the needling process, eliminating the need for manual cleaning interruptions. The needle cleaning material continuously removes resin deposits as needles operate, maintaining performance without stopping production.
Solution Approach 2:
The cleaning action occurs continuously during the needling operation rather than as periodic maintenance interruptions. This continuous cleaning ensures needle surfaces remain clear throughout the production run, maintaining consistent productivity and eliminating downtime.
3Manufacturing precision
If frequent needle changes are performed to maintain performance, then quality is preserved, but device complexity and maintenance costs increase
Solution Approach 1:
The self-cleaning mechanism extends needle service life by continuously removing resin deposits that would otherwise cause clogging and performance degradation. This reduces the frequency of needle replacements and maintenance operations.
Solution Approach 2:
The cleaning material performs preliminary cleaning action during normal operation, preventing resin buildup before it can cause clogging or performance loss. This proactive approach eliminates the need for reactive needle replacements.
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 production of thick, complex contour fibrous preforms with improved through thickness reinforcement by minimizing needle clogging, reducing maintenance, and enhancing production efficiency through automated cleaning mechanisms.
Implementation Method 1
a needle cleaning material, such as bristle brushes or rigid foam, which slides or rotates relative to the needle to clean the surface
Data Source
Figure 1~3
Figure 4A~4B
Figure 5A~5B
AI summary
An end effector (102, 202, 302) for the through thickness reinforcement of a fibrous preform (110) includes a needle cleaning material (220, 320) configured to contact a needle (108, 208, 308) to clean resin from the needle during or between through thickness reinforcement operations. The needle cleaning material may extend from a presser foot toward the needle. The needle cleaning material may slidingly engage the needle in response to movement of one of the needle or the presser foot moving (e.g., translating and/or rotating) with respect to the other of the needle or the presser foot.