Continuous Fiber Layup Process for Fiber-Reinforced Composite Preforms

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes an improved method for producing flat, fiber-reinforced semifinished products (preforms) used in fiber-plastic composite components. The innovation involves continuously depositing multiple layers of continuous fibers in individually desired orientations, directly and precisely matching the final part shape, without the need for additional carrier materials or side fixtures, and with minimal material waste. Additionally, reinforcing fibers can be selectively added to specific areas for enhanced, application-tailored strength.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of lightweight parts for aircraft structures and interiors
• Manufacturing of automotive components with optimized strength-to-weight ratios
• Fabrication of high-performance sports equipment, such as bicycle frames or helmets
• Creation of specialized composite panels for industrial or construction applications
• Mass production of custom-shaped composite blanks for further forming or molding operations

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly reduces material waste by directly creating parts in their final contours
• Enables cost-effective, high-volume production of composite preforms
• Allows for precise control of fiber orientation and local reinforcement for tailored mechanical properties
• Eliminates the need for extra carrier or supporting materials, reducing weight and production steps
• Increases design flexibility, supporting complex or application-specific geometries
• Improves manufacturing efficiency by enabling continuous processes and reducing finishing work
• Supports the development of lightweight, strong components critical for transportation and sports industries

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Inventors & Applicants

Patent Abstract

The present invention relates to a method for producing flat, fiber-reinforced semi-finished products for fiber-plastic composite components, in which continuous fibers are deposited in at least two layers one above the other during a continuous transport of these layers carried out by means of a layer transport mechanism, wherein the fiber orientation in a first layer of the at least two layers differs from the fiber orientation in at least one further layer of the at least two layers during the transport of the at least two layers. With the present invention, a method of this type is proposed in which the continuous fibers of the at least two layers are deposited straight without lateral support of the continuous fibers in a semi-finished product end contour form that is independent of the width of a transport belt used and/or the width of the layer transport mechanism, but does not extend over the width of the transport belt and/or the width of the layer transport mechanism, and are cut to length according to the respective width of the semi-finished product end contour form after at least partial deposition, and in at least one region of the semi-finished product end contour form, at least one continuous reinforcement fiber forming a reinforcement is laid on the layers.