Variable Density Preform Forming with Automated Alignment

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Solution Overview

Problem

Existing methods for fabricating composite panels are prone to variability in draw-in amounts during preforming, leading to increased scrap and higher production costs due to manual placement and sequential preforming and molding steps.

Innovation Solution

A one-step process that includes a tool with a binder and upper punch, utilizing tailored fiber placement and distance sensors to automate the alignment and impregnation of preforms, reducing scrap and material waste by ensuring precise positioning and controlled resin injection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual placement and sequential preforming and molding steps are used, then flexibility in handling preforms is maintained, but variability in draw-in amounts increases leading to increased scrap and higher production costs

Engineering Contradiction:

Improvedraw-in amount consistencyVSAvoidproduction cost and scrap rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines the preforming and molding operations into a single integrated step. The tool includes a binder with a first surface and a second surface at a different height, where the preform is positioned and then both preforming and molding occur simultaneously in one operation, eliminating the sequential steps and reducing variability in draw-in amounts

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The binder is designed with specific geometric features (first surface and second surface at different heights) that automatically guide and position the preform during the forming process. The preform's own geometry interacts with the binder's features to achieve proper alignment and consistent draw-in without requiring manual adjustment

Inventive Principle:

Principle #25Self-service

2Loss of substance

If tailored fiber placement with variable fiber density is implemented, then material efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvematerial wasteVSAvoidpreform structure and placement process

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The preform is constructed with different fiber densities in different regions - higher fiber density in areas requiring strength and lower fiber density in areas that will be folded or bent. This local variation optimizes material usage and reduces waste while the binder's geometric features handle the complexity of positioning such variable-density structures

Inventive Principle:

Principle #3Local quality

3Measurement precision

If automated alignment using distance sensors is implemented, then positioning accuracy is improved, but device complexity and initial cost increase

Engineering Contradiction:

Improvepreform positioning accuracyVSAvoidautomation system

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual positioning methods with automated alignment using distance sensors. The sensors detect the preform's position and the binder adjusts accordingly to achieve precise alignment, substituting mechanical manual adjustment with sensor-based automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Distance sensors provide real-time feedback on the preform's position relative to the binder, allowing the system to automatically adjust and maintain accurate positioning throughout the forming process, improving precision while managing complexity through automated control

Inventive Principle:

Principle #23Feedback

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

The method significantly reduces scrap and production costs by automating the preforming and molding process, ensuring accurate alignment and consistent fiber density distribution, resulting in higher quality composite panels with reduced material waste.

Implementation Method 1

An upper punch is moveable relative to the binder and the tool and includes a fluid passage configured to deliver resin to impregnate a preform arranged between the upper punch and the lower tool

Methodology Applied

Scientific EffectResin impregnation: Absorption (physical)

Data Source

PatentUS12257788B2Preform with variable fiber density, forming and molding tool and method for forming of composite materials

Publication Date: 2025.03.25 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method for fabricating a composite panel includes providing a preform including a peripheral edge portion and a central portion. The central portion has a first thickness, the peripheral edge portion has a second thickness that is greater than the first thickness, and a first step is arranged between the central portion and the peripheral edge portion. The method includes providing a tool including a binder defining a second step, an upper punch, and a lower tool; arranging the preform between the binder and the upper punch and the lower tool; shaping the preform using the tool; and injection molding the preform in the tool to create the composite panel.