Spiral Filament Binder Application on Dry Fibers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for applying binders to dry fibers in fiber layup machines are expensive and prone to machine fouling, especially in applications like the automobile industry, and require complex handling of pre-impregnated fibers or costly slitting processes.

Innovation Solution

A method using a fiberizing nozzle to apply a liquid or pasty binder in the form of spiral filaments onto dry fibers, allowing for efficient and precise application on both main faces of unidirectional fibers, which simplifies the process and reduces material costs by enabling on-line application without the need for pre-impregnation or heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If pre-impregnated fibers are used, then fiber cohesion is improved, but material cost increases and processing complexity increases

Engineering Contradiction:

Improvefiber cohesionVSAvoidprocessing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The binder is applied to the dry fibers before layup in a preliminary action at the creel, providing cohesion where needed while keeping the main layup process simple and equipment-free of complex heating or impregnation systems

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The binder application is localized to specific areas of the fiber (one or both faces) rather than requiring complete pre-impregnation of all fibers, reducing material cost and processing complexity while maintaining sufficient cohesion for the application

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If binder is applied by nozzle, then application precision is improved, but material cost increases

Engineering Contradiction:

Improvebinder application precisionVSAvoidmaterial cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The binder is applied in a controlled manner with specific parameters (amount, location, form) optimized to reduce material waste and cost while maintaining precision where it matters most for fiber cohesion and layup quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of applying binder uniformly to all fibers, the system applies binder partially to only those fibers or fiber faces that require it, reducing overall material cost while maintaining sufficient precision for the application

Inventive Principle:

Principle #16Partial or excessive action

3Manufacturing precision

If slitting process is used, then fiber width is calibrated, but machine fouling increases and production efficiency decreases

Engineering Contradiction:

Improvefiber width calibrationVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The slitting operation is extracted and eliminated from the process by using pre-cut fibers from the supplier, removing the source of machine fouling and production delays while maintaining the needed fiber width calibration

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fiber cutting and width calibration is performed in advance by the fiber supplier before delivery, eliminating the need for on-machine slitting operations that cause fouling and reduce productivity

Inventive Principle:

Principle #10Preliminary action

4Reliability

If heating is applied, then binder activation is improved, but energy consumption increases

Engineering Contradiction:

Improvebinder activationVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The binder formulation is designed with specific parameters (composition, viscosity, activation temperature) that allow it to become sufficiently active at lower temperatures or without heating, reducing energy consumption while maintaining reliable binder activation for fiber cohesion

Inventive Principle:

Principle #35Parameter changes

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

This method allows for cost-effective binder application, improving fiber cohesion and layup quality, reducing fouling, and enabling efficient production of composite material parts with enhanced adhesive properties and simplified equipment requirements.

Implementation Method 1

the nozzle is able to deliver the binder in the form of a spiral filament

Methodology Applied

Scientific EffectAtomization:

Implementation Method 2

one or several injection orifices supplied with pressurized gas, for example compressed air

Methodology Applied

Scientific EffectPressurized gas flow:

Data Source

PatentUS10894341B2Method for producing preforms with application of a binder to dry fiber, and corresponding machine

Publication Date: 2021.01.19 CORIOLIS GRP

AI summary

A method for producing preforms, by layup of fibers on a layup surface, comprising the application of a binder on at least one continuous flat dry fiber, comprising two opposite main faces, and the layup of the fiber provided with binder by means of a layup head in order to form a preform. The application of binder on a fiber is carried out by means of at least one fiberizing nozzle comprising a discharge orifice supplied with liquid or pasty binder, and one or several injection orifices supplied with pressurized gas, in such a way that said nozzle is able to deliver the binder in the form of a spiral filament, the spirals of filament being deposited on a first main face of the fiber running underneath the nozzle in order to obtain a fiber provided with filaments of binder.