Rapid Manufacturing of Tailored Preforms

Topic:

Clean Energy

Invention Reference Number

201804121

Traditional methods for producing composite materials with discontinuous fibers often lack precise control over the microstructure, affecting the mechanical and thermal properties of the final products. Common methods like resin transfer molding (RTM) and vacuum-assisted transfer molding (VARTM) are limited in their ability to control fiber orientation and distribution within the composite.

Description

The patented method introduces a novel approach to rapidly manufacture three-dimensional discontinuous fiber preforms. It involves depositing a polymeric material containing fibers onto a surface to form a tailored charge for compression molding. The polymeric material, which can be a thermoplastic or a reactive polymer, is designed to have a viscosity suitable for flow through an orifice while maintaining shape retention. Fiber alignment is achieved passively through shear forces or actively through orientation control, allowing for precise control over the mechanical properties of the final composite material. This method supports both single-layer and multi-layer deposition, accommodating fibers of various materials, lengths, and morphologies.

Benefits

Enhanced mechanical properties: Improved control over fiber alignment enhances the strength and stiffness of the final composite material.
Flexibility in fiber material and morphology: Supports a wide range of fiber types, including short and long fibers, allowing for customization based on specific application needs.
Efficient manufacturing: Rapid deposition process reduces production time and costs compared to traditional methods.
Versatile application: Suitable for producing complex parts with tailored microstructures, enhancing the performance of components in various industries.

Applications and Industries

Automotive: Manufacturing lightweight, high-strength components such as panels and structural parts.
Aerospace: Producing durable, high-performance materials for aircraft components.
Construction: Creating strong, lightweight building materials and structures.
Consumer electronics: Developing robust and lightweight casings and components.