System and method for preparing textiles with volumized tows for facilitating densification
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Solution Overview
Problem
Existing methods for fabricating carbon/ceramic composites, such as carbon brake disks, face challenges in achieving uniform fiber distribution and homogeneous densification due to high fiber volume and porosity, leading to non-uniform composite properties and poor fiber coverage during the textile process.
Innovation Solution
An air jet device is employed to alter the fiber volume and areal weight of a fiber bundle, comprising carbon/ceramic fibers, allowing for controlled fiber spreading and re-orientation, which is then processed using techniques like fabric weaving or multi-axial warp knitting to create a volumized fiber bundle for improved textile fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fiber bundle processing methods are used, then the fabrication process is simple, but the fiber distribution is non-uniform and porosity is high
Solution Approach 1:
The patent employs pneumatic devices including air knives and air jets to process fiber bundles. The air knife directs a sheet of high-velocity air across the fiber bundle surface to level and align fibers, while air jets create controlled turbulence to open and fluff the fiber bundle. These pneumatic methods replace traditional mechanical processing, achieving uniform fiber distribution and reduced porosity without significant increase in system complexity.
Solution Approach 2:
The patent changes the physical state and parameters of the fiber bundle through pneumatic action. The air jet device alters fiber velocity, orientation, and spacing by introducing controlled airflow parameters. This transforms the fiber bundle from a compact, non-uniform state to an expanded, uniformly distributed state suitable for high-quality composite fabrication.
2Strength
If fiber volume is increased to improve composite properties, then the composite strength improves, but the porosity increases leading to non-uniform densification
Solution Approach 1:
The air knife device directs a controlled sheet of high-velocity air across the fiber bundle, applying aerodynamic forces that level and align fibers while maintaining appropriate spacing. This pneumatic processing achieves uniform fiber distribution that enables homogeneous densification during subsequent composite fabrication, allowing high fiber volume content without excessive porosity.
Solution Approach 2:
The air jet device creates controlled turbulence and vibrational motion within the fiber bundle through pulsing or chaotic airflow patterns. This mechanical vibration effect opens up the fiber structure, separates individual fibers, and distributes them uniformly, preventing clumping and ensuring even densification throughout the composite while maintaining high fiber volume.
3Manufacturing precision
If fiber bundle is compacted to reduce porosity, then the densification improves, but the fiber damage increases
Solution Approach 1:
The air knife and air jet devices use pneumatic forces rather than mechanical contact to process the fiber bundle. The high-velocity air sheet and turbulent air jets apply aerodynamic pressure and shear forces that reduce porosity and improve densification uniformity without the mechanical contact that would cause fiber breakage or damage associated with traditional compaction methods.
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 approach results in more homogeneous fiber distribution and densification, reducing porosity and fiber damage, thereby enhancing the mechanical properties and uniformity of the final composite products, particularly in high-temperature applications like friction disks.
Implementation Method 1
An air jet device may be coupled between the supply of the fiber bundle and a desired lay down location. The air jet device is configured to alter at least one of a fiber volume or an areal weight of the fiber bundle. The air jet device is configured to form a length of volumized fiber bundle.
Data Source
AI summary
A transport of carbon fiber bundles, in as fabricated carbon fiber tow form, with in-line manipulation of the fiber bundles (spreading or spreading and volumization with manipulators) during fiber bundle transport is described herein. A method including positively transporting and placing a fiber bundle via a moveable fiber bundle delivery mechanism interposed between a fiber bundle supply and a fiber bundle delivery location, manipulating at least one of a fiber volume and an areal weight of the fiber bundle via an air jet device coupled between the fiber bundle delivery location and the fiber bundle supply, and controlling delivery of the fiber bundle tension from the fiber supply through an electronic unwinder is also described.