Textile Multilayer Composite Forming with Segmented Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing shaped textile multilayer composites in the automotive sector face challenges with material efficiency and cycle times, particularly in introducing heat into the material structure without damaging the layers, leading to suboptimal material consumption and processing times.
Innovation Solution
A method involving independent heating of individual layers, followed by lamination and stretching of the overall composite in a forming press, using controllable grippers to apply varying degrees of stretching, allowing for efficient temperature control and material deformation without layer damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heat is introduced into the material structure using conventional heating methods, then the material can be deformed and formed, but the cycle times are extended and material consumption increases
Solution Approach 1:
The heating process is segmented into independent heating of individual layers before lamination, rather than heating the complete multi-layer composite. This allows each layer to be heated efficiently and separately, reducing overall heating time and material waste.
Solution Approach 2:
The individual layers are heated in advance before being laminated together. This preliminary heating action enables subsequent rapid lamination and forming without requiring extended heating cycles for the complete composite structure.
2Ease of manufacture
If conventional heating methods are used to introduce heat into the material structure, then deformation is possible, but the layers may be damaged
Solution Approach 1:
By segmenting the heating process to heat individual layers separately before lamination, each layer can be heated to the appropriate temperature without overheating or damaging other layers. This controlled approach maintains layer integrity while enabling necessary deformation.
Solution Approach 2:
The heating parameters (temperature, time) are optimized for each individual layer based on its specific material properties. This allows precise control of thermal parameters to achieve deformation without exceeding damage thresholds for any layer.
3Productivity
If uniform stretching is applied to the overall composite, then the forming process is simple, but material efficiency is reduced
Solution Approach 1:
The stretching system uses individually controllable grippers that can apply dynamic, variable stretching forces across different zones of the composite. This allows optimization of material usage by stretching only where necessary while maintaining simple overall process flow.
Solution Approach 2:
Different zones of the composite receive different stretching intensities based on local requirements. The gripper system enables localized quality control of stretching, improving material efficiency by avoiding uniform over-stretching across the entire composite.
4Productivity
If individual layers are heated independently before lamination, then heat introduction is more efficient, but the process complexity increases
Solution Approach 1:
The heating system is segmented into separate heating zones or units for each layer, allowing independent heating control. This segmentation improves heating efficiency by targeting only the required layers while keeping the overall system modular and manageable.
Solution Approach 2:
The heating system is designed with multi-functional heating units that can heat different layers with the same basic equipment. This universality reduces actual device complexity while maintaining the efficiency benefits of independent layer heating.
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 enables significant material savings and efficient process control, ensuring strong and durable lamination while meeting automotive industry requirements for floor coverings, including reduced cycle times and improved material usage.
Implementation Method 1
a heating unit (3, 5), in particular a contact heating field and/or a radiant heating field
Implementation Method 2
a laminating unit (4), in particular a contact heating field, for laminating the at least two individual layers and/or single-layer composites
Implementation Method 3
The overall composite is then formed in a forming press (6) with a forming tool (9) located therein
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a method and to a device for producing formed textile multilayer composites. In particular, the invention relates to a method, in which a textile multilayer composite is laid, laminated, stretched and then formed into a top material of a floor covering in the automobile sector, with the proviso of material savings and cycle time reduction.