T-Shaped Non-Crimp Fabric Forming With Flange Ply Stabilization
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Solution Overview
Problem
Existing methods for producing T-shaped semifinished products from multi-ply non-crimp fabrics face challenges in maintaining the shape and position of fiber plies during the forming process, as the binding agent is activated after forming, allowing for little time to correct errors and leading to potential deformation.
Innovation Solution
A device comprising a web-shaping tool, forming tool, and a flexible film or tubular body with magnetic or fluid-based securing mechanisms to hold the flange portion in place until the binding agent is activated, ensuring the plies remain fixed and can be shaped into complex geometries without additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the binding agent is activated directly before the non-crimp fabric is formed, then the plies are connected and maintain their shape, but only little time remains for the forming operation and errors can be corrected with difficulty
Solution Approach 1:
The binding agent is activated in advance, before the forming operation begins. This preliminary activation causes the plies to connect and stiffen, providing shape stability during the forming process while still allowing time for corrections before the binding agent fully cures.
2Ease of operation
If the binding agent is activated only after the forming operation, then the plies can be easily deformed during forming, but the plies cannot retain their position until the binding agent is activated
Solution Approach 1:
The binding agent is activated preliminarily before completing the forming operation, providing early position retention for the plies while still allowing necessary deformations during the forming process.
Solution Approach 2:
The system transitions from a flexible state during forming to a stabilized state as the binding agent activates, dynamically adjusting the rigidity of the ply structure to match the process requirements at different stages.
3Reliability
If additional heat sources are used to activate the binding agent after forming, then the plies are connected before resin impregnation, but the process requires additional equipment and time
Solution Approach 1:
The heating function is merged with the existing forming tool, combining the shape-forming and binding agent activation functions into a single integrated device, thereby reducing the number of separate heat sources needed.
Solution Approach 2:
The forming tool is designed to perform multiple functions: shaping the non-crimp fabric and activating the binding agent through integrated heating elements, making the tool universal for both forming and curing operations.
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
The solution effectively secures the flange portion of the non-crimp fabric in its formed shape until the binding agent cures, preventing deformation and allowing for precise manufacturing of T-shaped semifinished products with complex profiles.
Implementation Method 1
a magnetic force is generated between the film and the web-shaping tool, the magnetic force drawing the flexible film onto the web-shaping tool such that the flexible film secures the flange portion formed into the flange
Implementation Method 2
binding agents which are activated by heat are known
Data Source
AI summary
Devices and methods for producing a T-shaped semifinished product from a multiply non-crimp fabric with reinforcing fibers for a composite material. The product has a web and a flange. The device includes a web forming tool, with which a web portion of the non-crimp fabric is clamped in place, a forming tool, with which plies of a flange portion of the non-crimp fabric are split into two parts, a depositing device, with which a tube body is deposited on the flange portion formed into the flange, a holding tool, with which a clearance between the holding tool and the flange is formed, and a filling device, with which the tube body is filled with a gas such that the tube body fills the clearance and firmly holds the flange portion formed into the flange, and alternatively, a magnetic force can be generated between a sheet and the web forming tool.