TFP Fiber Preform Release Layer and Melted Fixing Threads
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Solution Overview
Problem
The TFP process for producing fiber preforms introduces auxiliary components like backing layers and fixing threads that are not functional in the final composite component, causing weight issues, delaminations, and impairing mechanical properties due to misalignment and damage during the sewing process.
Innovation Solution
A release layer with nonstick properties is applied to the backing layer, allowing the backing layer to be detached without damaging the fiber strands, and the fixing threads are partially melted to secure the fiber strands' position, enabling easy detachment of the backing layer and reducing flaws in the fiber preform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the TFP process uses backing layers and fixing threads to attach fiber strands, then the fiber strands can be aligned and fixed in position, but the auxiliary components increase weight and cause delaminations in the final composite component
Solution Approach 1:
The patent removes the backing layer from the final fiber preform after the TFP process is complete. The fiber strands are first fixed to the backing layer during manufacturing, then the backing layer is stripped away leaving only the aligned fiber strands. This extracts the harmful auxiliary component while preserving the beneficial fiber alignment.
Solution Approach 2:
The backing layer serves as a temporary carrier during the TFP process and is then discarded in a controlled manner. The fixing threads are also removed or melted away after serving their purpose of aligning and securing the fiber strands during manufacturing. This allows recovery of the fiber preform without the weight penalty of permanent auxiliary components.
2Stability of the object's composition
If fixing threads are used to attach fiber strands on the backing layer, then the fiber strands are secured in position, but the fixing threads create flaws and damage to the fiber preform
Solution Approach 1:
The fiber strands are aligned and positioned using fixing threads during the TFP manufacturing process. The fixing threads perform their stabilizing function during construction, then are removed or melted away before the final composite is produced. This preliminary use of fixing threads allows proper fiber strand positioning without leaving permanent flaws in the final product.
Solution Approach 2:
The fixing threads are made of material that changes state under specific conditions (e.g., melts at elevated temperatures). This parameter change allows the fixing threads to be easily removed after serving their positioning function, eliminating the flaws they would otherwise introduce into the final composite structure.
3Volume of moving object
If multiple layers of fiber preforms are stacked to achieve greater material thickness, then large thicknesses can be produced, but the number of auxiliary components increases and weight increases
Solution Approach 1:
When multiple fiber preform layers are stacked to achieve greater thickness, the backing layers are removed from each layer. This extraction of auxiliary components from each individual layer prevents the cumulative weight increase that would otherwise occur with multiple stacked backing layers, while still achieving the desired total thickness through the fiber layers themselves.
4Productivity
If conventional sewing machines are used for the TFP process, then automatic production is enabled, but the sewing needle damages the fiber strands and creates wave formation
Solution Approach 1:
The patent replaces the mechanical needle-based attachment method with a thermal bonding process. Instead of using a sewing needle that mechanically pierces and damages fibers, heat is applied to melt the fixing threads and bond them to the fiber strands. This substitution eliminates the mechanical damage and wave formation caused by needle penetration while maintaining automatic production capability.
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 method ensures the fiber preform has optimal mechanical properties with improved alignment and reduced weight, eliminating delaminations and flaws, and allows for the production of composite components with large material thicknesses and isotropic fiber orientation.
Implementation Method 1
A release layer with nonstick properties is applied to the backing layer, allowing the backing layer to be detached without damaging the fiber strands
Implementation Method 2
the fixing threads are partially melted to secure the fiber strands' position, enabling easy detachment of the backing layer
Data Source
AI summary
A method for producing single- or multi-layered fiber preforms by the TFP process with fiber strands, aligned substantially to be oriented with the flux of force, laid on a backing layer and attached by fixing threads, to form a fiber preform with a desired material thickness and without a backing layer. A release layer is applied at least in certain regions to the backing layer and, after completion of the TFP process, the fiber preform is introduced into a fixing device, in which at least some of the fixing threads are melted. Subsequently the backing layer, separated from the fiber preform by the release layer, is detached from the fiber preform. The fiber preforms have a virtually optimum fiber structure without flaws along with a desired material thickness and are predestined for the production of composite components for load-bearing components that must withstand high mechanical loads.