Textile Reinforcement Framework with Adjustable Surface Mass
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing reinforcement frames for composite materials face limitations in adjusting the surface mass of the appearance layer and often result in significant scrap due to non-uniform veil widths, leading to increased costs and inefficiencies.
Innovation Solution
A process involving a unidirectional reinforcing ply covered with a sewing/knitting step, where the appearance layer is composed of parallel threads of lower tenacity extending from one selvedge to the other, allowing for precise adjustment of surface mass and orientation, replacing traditional surface veils with individual wires oriented between 0° and 90°, and using textured yarns for enhanced coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional surface veil is used to cover the reinforcing ply, then the appearance and surface quality are improved, but the surface mass cannot be flexibly adjusted and significant scrap is generated due to width mismatches
Solution Approach 1:
The patent divides the traditional continuous surface veil into discrete parallel threads that can be independently controlled. Each thread is deposited separately across the reinforcing ply, allowing precise control over the number, spacing, and orientation of threads to achieve desired surface mass without generating scrap material.
Solution Approach 2:
The patent introduces dynamic adjustability in the appearance layer by allowing the thread spacing, orientation angle, and density to be varied during the deposition process. This enables flexible control of surface mass to match different reinforcement widths and requirements, eliminating the need for pre-cut veils that generate scrap.
2Adaptability or versatility
If a surface veil with fixed characteristics is used, then the application process is simplified, but the ability to adjust surface mass and adapt to different reinforcement specifications is limited
Solution Approach 1:
The patent creates a universal appearance layer system using parallel threads that can be deposited in various orientations (0° to 90° relative to warp direction) and densities. A single thread deposition mechanism can serve multiple functions by adjusting thread spacing and orientation, replacing the need for multiple specialized veils with different fixed characteristics.
Solution Approach 2:
The patent enables continuous adjustment of surface mass by changing parameters such as thread spacing, thread density, and orientation angle during the deposition process. This allows the same basic structure to adapt to different reinforcement specifications without requiring physically different veil products.
3Strength
If traditional surface veils are used to compensate for seam effects and resin distribution, then adhesion and impregnation are improved, but the isotropic nature prevents reinforcement in specific directions
Solution Approach 1:
The patent applies local quality by allowing the appearance layer threads to have different orientations in different regions. Threads can be oriented at specific angles (including 0° and 90° relative to warp direction) to provide reinforcement in preferred directions while still maintaining the benefits of surface coverage and resin distribution control.
Data Source
Figure 1
Figure 2
AI summary
The process comprises depositing a unidirectional reinforcement web (1, 2, 4) of high tenacity yarn (3, 5), covering a web of a decorative layer (6), and subjecting an assembly to stitching/knitting step to ensure cohesion of the superimposed layers. The decorative layer is deposited in the form of yarn web (7) with tenacity that is less than the tenacity of unidirectional reinforcement web of high tenacity yarn, and has an angle of 30-90[deg] with respect to the direction of chain. The yarn web is parallel and extends from one edge (9) to the other of a textile reinforcement structure. The process comprises depositing a unidirectional reinforcement web (1, 2, 4) of high tenacity yarn (3, 5), covering a web of a decorative layer (6), and subjecting an assembly to stitching/knitting step to ensure cohesion of the superimposed layers. The decorative layer is deposited in the form of yarn web (7) with tenacity that is less than the tenacity of unidirectional reinforcement web of high tenacity yarn, and has an angle of 30-90[deg] with respect to the direction of chain. The yarn web is parallel and extends from one edge (9) to the other of a textile reinforcement structure. The unidirectional reinforcement web of high tenacity yarn is superimposed with different orientations between two successive layers. An independent claim is included for a textile reinforcement structure.