Textile Winding Spacer Elements for Thickness Variation
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Solution Overview
Problem
The challenge in fabricating textile structures of varying thickness is maintaining constant tension during winding, as the take-up length of warp yarns in thicker portions increases disproportionately compared to thinner portions, leading to uneven ratios and potential deformations.
Innovation Solution
Interposing spacer elements, such as cellular structures or textile strips, between adjacent turns on the mandrel during winding to compensate for thickness variations, ensuring the ratio of warp yarn lengths remains constant across different thickness portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the fiber texture is wound under tension onto the mandrel to maintain constant tension, then the tension control is improved, but the take-up length of warp yarns in thicker portions increases disproportionately compared to thinner portions
Solution Approach 1:
A tension control device is introduced as an intermediary mechanism between the fiber texture and the mandrel. This device includes a tensioning roller and a tension control mechanism that actively regulates the tension applied to the fiber texture during winding, preventing disproportionate take-up length increases in thicker portions while maintaining constant tension control.
Solution Approach 2:
The tension control device dynamically adjusts the tension parameter during the winding process. By changing the tension applied to different portions of the fiber texture based on their thickness, the system prevents the take-up length ratio from deviating, thereby maintaining manufacturing precision while managing tension forces.
2Manufacturing precision
If the take-up length of warp yarns in thicker portions is controlled to match thinner portions, then the warp yarn length ratio remains constant, but the tension distribution becomes uneven
Solution Approach 1:
The tension control device is designed as a dynamic system that continuously adjusts tension during winding. The tensioning roller can vary the applied force in real-time based on the local thickness of the fiber texture, allowing the system to maintain constant warp yarn length ratios while adapting tension distribution to match the varying geometry of the composite structure.
Data Source
AI summary
A method of fabricating a textile structure of varying thickness including using a loom to weave a fiber texture in the form of a strip extending lengthwise along a longitudinal axis and widthwise along an axis perpendicular to the longitudinal axis, and causing the texture to be wound under tension onto a mandrel. The texture includes a portion presenting extra thickness. During the winding of the texture, a spacer element is interposed between adjacent turns of the fiber texture onto the mandrel. Each spacer element extends in the width direction of the texture over a portion thereof situated outside the portion of extra thickness and presenting, over the portion of the texture situated outside the portion of extra thickness, a thickness that corresponds at least to the difference between thicknesses of the portion of extra thickness and of the portion of the texture situated outside the portion of extra thickness.