Thermoplastic Composite Preform Additive Welding
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Solution Overview
Problem
Existing methods for manufacturing composite parts with continuous fiber reinforcement extending along more than two faces face challenges in maintaining fiber continuity and require significant tooling and additional elements, limiting their applicability in industries like aeronautics.
Innovation Solution
A method involving additive manufacturing to deposit a demarcated layer of thermoplastic polymer with metal particles on the preform, followed by welding, which allows for precise positioning and assembly of composite parts with reduced tooling requirements, enabling the creation of complex geometries like dihedral or trihedral shapes without fiber discontinuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional assembly techniques such as welding or co-curing are used to assemble multiple elements to achieve complex geometries, then fiber continuity can be maintained, but significant tooling is required and the manufacturing process becomes complex
Solution Approach 1:
The preform is pre-assembled with continuous fiber reinforcement extending along multiple faces before final assembly. This preliminary configuration of fibers across multiple faces enables complex geometries to be achieved without requiring significant tooling during the final assembly process, as the fiber continuity is already established in the preform stage
Solution Approach 2:
The manufacturing process is divided into separate stages: preform assembly with continuous fibers, demarcation of assembly zones, and final thermoplastic polymer deposition. This segmentation allows complex geometries to be built incrementally without requiring all tooling to be present simultaneously, reducing overall device complexity
2Stability of the object's composition
If other elements are added to a first preform using conventional assembly techniques to achieve multi-face configurations, then fiber continuity can be retained, but the manufacturing process requires significant tooling and becomes difficult or impossible
Solution Approach 1:
The invention changes the physical state of the polymer from thermosetting to thermoplastic, enabling the polymer to be melted and welded using simple heating methods. This parameter change allows easy assembly of multi-face configurations while maintaining fiber continuity, eliminating the manufacturing difficulties associated with conventional techniques
Solution Approach 2:
A thermoplastic polymer layer is deposited as an intermediary material in assembly zones to join preform elements. This intermediary polymer enables easy welding and assembly while maintaining fiber continuity across joints, avoiding the manufacturing complexity of conventional assembly techniques
3Ease of manufacture
If dynamic welding with metal susceptor is used to assemble composite parts, then assembly can be achieved, but metal susceptor must be integrated into the parts
Solution Approach 1:
The metal susceptor is extracted from the composite part structure and replaced with a thermoplastic polymer layer that can be welded using simple heating. This removal of the susceptor eliminates the need for integrating metal components into the composite parts, simplifying the manufacturing process while maintaining assembly capability
4Shape
If over molding by injection is used to create raised features on composite parts, then features can be added, but it requires injection mold development and is limited to small dimensions produced in very large quantities
Solution Approach 1:
The thermoplastic polymer is deposited locally in demarcated assembly zones rather than requiring full-part injection molding. This localized approach enables the creation of raised features and complex geometries on parts of any size without requiring expensive injection mold development, making the process adaptable to various dimensional requirements including large aeronautical components
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
Enables the precise positioning and assembly of composite parts with continuous fiber reinforcement, reducing tooling needs and allowing for the creation of complex shapes like dihedral or trihedral parts, enhancing manufacturing efficiency and adaptability in industries such as aeronautics.
Implementation Method 1
a step (i) of depositing on one of the faces of the preform a demarcated layer of thermoplastic polymer using an additive manufacturing method
Implementation Method 2
a step (ii) of making a welded assembly by melting the layer of thermoplastic polymer deposited during step (i)
Implementation Method 3
the welding process is a dynamic process. For example, such a process uses induction or microwave heating, wherein the material can be heated locally by using the susceptor effect created by the particles comprised in the layer of polymer
Data Source
AI summary
A method for manufacturing a composite part with continuous fiber reinforcement and a polymer matrix from a composite preform. On one of the faces of the composite preform, a demarcated layer of thermoplastic polymer is deposited using an additive manufacturing method.