Water-Soluble Fixing Threads for TFP Fiber Preforms
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Solution Overview
Problem
The TFP process for producing fiber preforms includes fixing threads and backing layers that are unnecessary in the final composite component, causing weight issues and impairing mechanical properties due to their presence and removal difficulties.
Innovation Solution
A method where fiber strands are laid on a water-soluble backing layer and attached with a water-soluble fixing thread, which are then dissolved and flushed out using water, allowing for ideal fiber alignment and weight reduction, followed by impregnation with a curable polymer material in a fixing device that also serves as a mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixing threads and backing layers are used in the TFP process, then fiber strands can be properly attached and positioned, but the weight of the composite component increases and mechanical properties are impaired
Solution Approach 1:
The patent extracts and removes the non-functional fixing threads and backing layers from the final composite component through a dissolution process. Water is introduced to dissolve water-soluble adhesives or matrices that temporarily held the fiber strands during manufacturing, leaving only the functional fiber reinforcement in the final product. This eliminates dead weight while maintaining the structural integrity achieved during the TFP process.
2Ease of manufacture
If fixing threads and backing layers are used in the TFP process, then fiber strands can be attached during manufacturing, but the mechanical properties of the composite component are impaired due to their presence
Solution Approach 1:
The patent removes the interfering fixing threads and backing layers through selective dissolution. Water-soluble adhesives or matrices used during manufacturing are dissolved by introducing water into the mold cavity, allowing the non-functional elements to be washed away while the functional fiber strands remain intact. This extraction eliminates stress concentration points and defects that would otherwise compromise the mechanical strength of the final composite component.
Solution Approach 2:
The patent changes the chemical composition parameters of the temporary bonding material to make it water-soluble. By selecting adhesives or matrices that dissolve in water, the manufacturing process can utilize easily removable bonding agents that leave no residual impact on the final product's mechanical properties. This parameter change enables complete removal of non-functional elements without requiring complex mechanical removal processes.
3Volume of moving object
If multi-layered fiber preforms are produced to achieve greater material thickness, then the desired thickness can be obtained, but more fixing threads and backing layers are required increasing weight and complexity
Solution Approach 1:
The patent applies extraction to remove all non-functional elements from multi-layered fiber preforms. By dissolving water-soluble adhesives or matrices in multi-layered structures, the process eliminates the cumulative weight and complexity of multiple backing layers and fixing threads that would otherwise be required to maintain the multi-layered configuration. The result is a simplified single-integrated structure with the desired thickness but without the parasitic elements.
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 produces fiber preforms with quasi-isotropic properties and significant weight savings by removing non-functional elements, ensuring optimal fiber alignment and mechanical properties without impairing the resin matrix, especially beneficial for multi-layered preforms.
Implementation Method 1
at least one of the fixing thread and the backing layer being formed by a water-soluble material... the fixing device is flowed through by water as the solvent, in order to remove said at least one of the fixing thread and the backing layer by dissolving and flushing out
Implementation Method 2
the at least one fiber preform is dried in the fixing device by heat being supplied
Implementation Method 3
impregnated with a curable polymer material, for example a polyester resin, an epoxy resin or the like, to form the finished component
Data Source
AI summary
Disclosed is a method for producing single- or multi-layered fiber performs by the TFP process with fiber strands which are aligned substantially such that they are oriented with the flux of force, are laid on at least one backing layer and are attached by at least one fixing thread. After completion of the TFP process, at least one fiber preform is introduced into a fixing device to secure the position of the fiber strands and the fixing threads and/or the backing layers are at least partially removed. As a result of the preferably complete removal of the fixing threads and/or the backing layer from the fiber preform, the latter has virtually ideal mechanical, quasi isotropic properties. In a preferred variant, the fixing threads and/or the backing layers are formed by a water-soluble material, so that they can be completely dissolved by water as the solvent and flushed out.