Thermal Spraying Yarn Bonding for Composite Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing fiber-reinforced composite materials with complicated or three-dimensional structures are limited by the inability to effectively maintain yarn position during solidification and are time-consuming.
Innovation Solution
A thermal spraying process is used to apply a thermally fusible material to yarns at contact points, allowing for precise bonding and rapid connection while the material is still in a plastic or molten state, utilizing a plasma jet for efficient deposition and ensuring good adhesion with the matrix material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermally fusible material is applied to yarns and then heated for solidification, then yarns can be connected to form laid structures, but the process is time-consuming due to the cooling phase required for solidification
Solution Approach 1:
The invention changes the physical state parameter of the thermally fusible material by maintaining it in a plastic or molten state during the laying process, eliminating the need for a subsequent cooling phase. This is achieved by applying the material in a softened state and completing the laying operation while the material remains pliable, thus resolving the time-consuming cooling requirement while maintaining bond strength.
Solution Approach 2:
The thermally fusible material is applied to the yarns in advance in a plastic or molten state before the laying operation is completed. This preliminary application ensures that the bonding material is already in place and in the optimal state for bonding when the yarns are positioned, eliminating the need for post-laying cooling and solidification time.
2Strength
If yarns are laid and thermally fusible material is applied, then yarns can be connected, but complicated and three-dimensional structures cannot be produced because yarns slip or slide during solidification
Solution Approach 1:
By maintaining the thermally fusible material in a plastic or molten state during laying, the invention ensures that the material remains pliable and adaptive to yarn movements, allowing complicated and three-dimensional structures to be formed without the yarns slipping or sliding. The material sets in this adjusted position, achieving both structural complexity and positional precision.
Solution Approach 2:
The invention introduces dynamic flexibility by keeping the bonding material in a plastic or molten state during the laying process, allowing the material to adapt to and fix the yarns in their final positioned state. This dynamic state enables the formation of complex geometries while maintaining precise yarn positioning, as the material can flow and conform during placement then solidify in the desired configuration.
3Strength
If thermally fusible material is applied in powder form and then heated, then yarns can be connected, but the process is time-consuming
Solution Approach 1:
The invention changes the application state of the thermally fusible material from powder form to a plastic or molten state before application. This parameter change eliminates the need for subsequent heating and melting steps, as the material is already in the optimal state for bonding. The material can be directly applied to the yarns and will set as the laying process completes, significantly increasing production speed while maintaining bond strength.
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 enables the production of complex and three-dimensional structures in a shorter time by ensuring a strong bond between yarns and reducing the cooling phase, facilitating the creation of high-quality fiber-reinforced composite materials.
Implementation Method 1
a thermally meltable material is applied to the yarns at least at their contact or crossing points using a thermal spraying process
Implementation Method 2
processes that melt the thermally fusible material and, if possible, throw it in the form of tiny droplets onto the deposit body and/or onto the yarn
Implementation Method 3
If a plasma jet is used as the energy carrier
Implementation Method 4
the yarns are brought together while the thermal spraying applied thermally fusible material is still in a plastic or molten state
Data Source
AI summary
The invention relates to a method for producing reinforced placed structures of threads, characterized in that a thermally meltable material is applied to the threads at least at the contact or crossing points of said threads by means of a thermal spraying method, whereupon the threads are being brought together. The invention also relates to a method for producing a fibre-reinforced composite material which is characterized in that first the above-mentioned placed structures are produced which are subsequently formed under the effect of heat and pressure, eventually by adding other thermally meltable material, in order to produce fibre-reinforced composite material.