Variable-Geometry Reinforcement Profiles for Continuous Pultrusion
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Solution Overview
Problem
Existing pultrusion processes for manufacturing fibre-reinforced materials with constant cross-sectional geometry are inefficient and unsustainable, requiring modular production of multiple parts with different geometries that need manual assembly, leading to waste and high costs.
Innovation Solution
A method and apparatus for manufacturing reinforcement profiles with variable cross-sectional geometry by passing fabric layers through a heated die with adjustable geometry, allowing continuous production of profiles that match non-uniform structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If modular production with constant cross-sectional geometry is used, then manufacturing simplicity is maintained, but productivity decreases and waste increases
Solution Approach 1:
The die geometry is made variable along the length direction, allowing continuous change of cross-sectional geometry during the pultrusion process. This dynamic geometric capability enables single-continuous production of profiles matching non-uniform structures, resolving the contradiction between manufacturing simplicity and productivity.
Solution Approach 2:
A single die with variable cross-sectional geometry performs the function of multiple constant-geometry dies simultaneously. The die can produce different cross-sectional profiles at different positions along the reinforcement profile, eliminating the need for separate modular production and manual assembly, thus improving productivity while maintaining manufacturing simplicity.
2Device complexity
If modular production with manual assembly is used, then manufacturing complexity is reduced, but loss of time increases
Solution Approach 1:
The invention merges multiple production steps (production of different geometric modules and their assembly) into a single continuous pultrusion process. The variable cross-sectional die produces the complete non-uniform profile in one continuous operation, eliminating manual assembly operations and significantly reducing time loss while keeping device complexity manageable.
3Adaptability or versatility
If modular production is used, then adaptability to different geometries is achieved, but loss of substance increases
Solution Approach 1:
The variable cross-sectional die dynamically adjusts the geometry along the length of the profile, allowing the reinforcement profile to precisely match the target non-uniform structure. This eliminates excess material that would result from modular assembly and trimming, reducing material waste while maintaining geometric adaptability.
4Manufacturing precision
If constant cross-sectional geometry is used, then manufacturing precision is maintained, but adaptability to non-uniform structures decreases
Solution Approach 1:
The die geometry varies continuously along the length direction while maintaining precise control over the cross-sectional shape at each position. This dynamic geometric capability enables the production of reinforcement profiles with precise non-uniform cross-sections that match complex structures, simultaneously achieving manufacturing precision and geometric adaptability.
Solution Approach 2:
Different cross-sectional geometries are applied at different locations along the reinforcement profile according to the specific requirements of the target structure. Each section of the profile has optimized local geometry, achieving high adaptability to non-uniform structures while maintaining precise control over the fiber-reinforced material properties at each location.
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 cost-effective, efficient, and sustainable production of reinforcement profiles with variable geometry, reducing waste and assembly time by producing continuous profiles that fit non-uniform structures directly, thereby reducing waste and assembly time.
Implementation Method 1
passed through a heated die to consolidate the two or more fabric layers and polymer into a reinforcement profile
Implementation Method 2
heated die that cures the thermosetting resin and provides a final product
Data Source
Figure 1A~1B
Figure 2A~2D
Figure 3A~3D
AI summary
Method for manufacturing reinforcement profiles (110) having variable profile cross-sectional geometry (112), the method comprises a step of - passing two or more fabric layers (120) with a polymer through a heated die (10) to consolidate the two or more fabric layers (120) and polymer into a reinforcement profile (110), the heated die (10) having a die cross-sectional geometry (12) providing the reinforcement profile (110) with a profile cross-sectional geometry (112); and - varying the die cross-sectional geometry (12) to vary the profile cross-sectional geometry (112) along the reinforcement profile (110).