Description:FIELD OF THE INVENTION

[0001] The present invention relates to a composite material manufacturing system that is capable of enhancing operational efficiency, ensuring consistent quality, and mitigating risks associated with manual handling and hazardous materials.

BACKGROUND OF THE INVENTION

[0002] Composite materials are engineered materials made from two or more constituent materials with significantly different physical or chemical properties. These materials are combined to produce a final product that exhibits enhanced performance characteristics not achievable by any of the individual components alone. Typically, composites consist of a matrix material, which serves as a binder, and reinforcement materials, which provide strength and other desired properties. The matrix can be a polymer resin, metal, ceramic, or even another composite material, while reinforcements often include fibers, particles, or flakes embedded within the matrix. By strategically selecting and combining these materials, composites can achieve properties such as high strength-to-weight ratio, durability, corrosion resistance, and thermal stability. This versatility makes composites invaluable in industries ranging from aerospace and automotive to construction, sports equipment, and consumer goods, where lightweight, strong, and customizable materials are essential for innovation and performance.

[0003] Traditional methods of manufacturing composite materials typically involve manual processes that are labor-intensive and pose several drawbacks. One common approach is hand lay-up, where layers of reinforcement materials (such as fiberglass or carbon fiber) are manually placed in a mold and impregnated with resin using brushes or rollers. This method is time-consuming and highly dependent on the skill of the operator, leading to variations in resin distribution and fiber alignment, which can affect material strength and consistency. Vacuum bagging is another technique where the laid-up materials are placed in a vacuum-sealed bag to remove air and consolidate the laminate. While it improves resin distribution, it requires significant labor and time for setup and curing. Compression molding involves placing pre-impregnated materials in a heated mold under pressure to cure. This method offers better control over part dimensions and surface finish but is limited in complex part geometries and requires costly tooling. Overall, traditional methods of composite manufacturing are hindered by high labor costs, variability in quality, limited automation, and challenges in scaling for mass production. These drawbacks highlight the need for advanced manufacturing techniques that can automate processes, enhance consistency, reduce cycle times, and broaden the application range of composite materials across various industries.

[0004] AU2020201610B2 discloses a method of fabricating a composite structure, the method comprising stitching dry fibre layers (24a, 24b, 24c) together into a stitched stack (22) of dry fibre layers having varying fibre orientations; infusing the stack (22) of dry fibre layers with a resin; thermally curing the stitched stack (22) of dry fibre layers; and melting the stitching during thermal curing of the stitched stack (22) of dry fibre layers.

[0005] US11084269B2 discloses a composite structure comprises stacked sets of laminated fiber reinforced resin plies and metal sheets. Edges of the resin plies and metal sheets are interleaved to form a composite-to-metal joint connecting the resin plies with the metal sheets.

[0006] Conventionally, many systems had been developed that is capable of manufacturing composite material, however none of the above mentioned cited prior arts are, capable of streamlining fabrication processes through automation and integration of advanced technologies to reduce production time and labor costs, achieving uniformity in composite material properties by maintaining precise control over parameters such as tension distribution, drying conditions, and cutting accuracy and minimizing operator exposure to hazardous materials and operational risks through automated handling and containment systems.

[0007] In order to overcome the aforementioned drawbacks, there is a requirement to develop a system capable of streamlining fabrication processes through automation and integration of advanced technologies to reduce production time and labour costs, achieving uniformity in composite material properties by maintaining precise control over parameters such as tension distribution, drying conditions, and cutting accuracy and minimizing operator exposure to hazardous materials and operational risks through automated handling and containment systems.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a system capable of streamlining fabrication processes through automation and integration of advanced technologies to reduce production time and labor costs.

[0010] Another object of the present invention is to develop a system that is capable of achieving uniformity in composite material properties by maintaining precise control over parameters such as tension distribution, drying conditions, and cutting accuracy.

[0011] Yet another object of the present invention is to develop a system that is capable of minimizing operator exposure to hazardous materials and operational risks through automated handling and containment systems.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a composite material manufacturing system presented herein is a comprehensive solution intended to automate and optimize the process, thus the system lowers the risks associated with manual handling and minimizes exposure to hazardous materials, which not only increases operational efficiency and productivity but also improves safety.

[0014] According to an embodiment of the present invention, a composite material manufacturing system comprises of a removal soaking container, designed as a drawer with curved sliding shapes for easy insertion and removal of fabric materials immersed in a Epoxy solution, this container's durable construction and detachable sections ensure longevity and facilitate maintenance, enhancing operational efficiency and safety by minimizing manual handling and exposure to hazardous vapors.

[0015] According to another embodiment of the present invention, the proposed system further comprises of a tension fabric roller, equipped with a spring-based mechanism system that allows for precise adjustment of tension levels across various fabric types, this capability ensures uniform tension distribution, crucial for maintaining the quality and integrity of composite materials throughout the manufacturing process, the system further includes a nail roller with a chuck mechanism, which securely holds and rolls fabric using pin-sized nails, optimizing workflow efficiency and reducing manual labor, additionally, the fan dryer system expedites drying times with adjustable airflow and temperature controls, enhancing overall productivity while conserving energy, finally, the programmable fabric cutter facilitates accurate and customizable cuts, accommodating diverse fabric shapes and sizes to meet specific composite material requirements with precision and consistency, together, these components constitute a comprehensive solution that improves safety, efficiency, and product quality in composite material manufacturing.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a composite material manufacturing system;
Figure 2 illustrates a front view of the proposed system;
Figure 3 illustrates a right side view of the proposed system;
Figure 4 illustrates a left side view of the proposed system;
Figure 5 illustrates a top view of the proposed system;
Figure 6 illustrates a bottom view of the proposed system; and
Figure 7 illustrates a back view of the proposed system.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to a composite material manufacturing system system described herein represents a comprehensive solution designed to automate and optimize the production of composite materials using Epoxy solution. By integrating innovative features such as the removal-soaking container, tension fabric roller, nail roller with chuck mechanism, fan dryer system, and programmable fabric cutter, the system addresses key challenges associated with manual processes in laboratory settings. This approach not only enhances operational efficiency and productivity but also improves safety by minimizing exposure to hazardous substances and reducing manual handling risks.

[0022] Referring to figure 1 illustrates an isometric view of a composite material manufacturing system;

[0023] Referring to Figure 2 illustrates a front view of the proposed system;

[0024] Referring to Figure 3 illustrates a right side view of the proposed system;

[0025] Referring to Figure 4 illustrates a left side view of the proposed system;

[0026] Referring to Figure 5 illustrates a top view of the proposed system;

[0027] Referring to Figure 6 illustrates a bottom view of the proposed system; and

[0028] Referring to Figure 7 illustrates a back view of the proposed system.

[0029] The composite material manufacturing system includes a removal-soaking container designed to automate and improve the immersion, straightening, and drying processes of fabric submerged in an Epoxy-resin solution. The soaking container is configured as a drawer with curved sliding shapes for casing, allowing for easy insertion and removal of fabric materials. The container is constructed with materials that ensure longevity and convenience, with all sections designed to be detachable for maintenance purposes. This design feature not only enhances durability but also facilitates ease of cleaning and upkeep, essential in laboratory environments where cleanliness and safety are paramount.

[0030] The removal-soaking container within the composite material manufacturing system functions as a pivotal component designed to automate and streamline the immersion, straightening, and drying processes of fabric submerged in an Epoxy-resin solution. Configured as a drawer with curved sliding shapes for casing, the container offers a user-friendly interface for inserting and removing fabric materials effortlessly. Its robust construction ensures longevity and convenience, with all sections meticulously engineered to be detachable for straightforward maintenance and cleaning. This design not only promotes durability but also enhances operational efficiency in laboratory settings. By automating the immersion process, the removal soaking container eliminates the need for manual handling of fabric, thereby reducing exposure to potentially harmful vapors and minimizing operational risks. It represents a significant advancement in composite material manufacturing, providing a controlled environment that optimizes fabric treatment while adhering to stringent safety standards.

[0031] Integral to the system is a tension fabric roller equipped with a spring-based mechanism system. This roller is designed to create customized tension distribution over various types of fabric materials. By adjusting the tension settings, users can achieve uniform tension distribution, which is critical for enhancing the overall quality of composite materials produced. The ability to tailor tension levels according to fabric type ensures consistent performance and reliability throughout the manufacturing process.

[0032] The tension fabric roller in the composite material manufacturing system plays a crucial role in ensuring precise and uniform tension distribution across various types of fabric. Equipped with a sophisticated spring-based mechanism system, the roller allows operators to adjust tension settings according to specific fabric characteristics and production requirements. This customization capability ensures that fabric materials are uniformly stretched and secured during processing, thereby enhancing the overall quality and performance of the composite materials produced. By maintaining consistent tension levels, the tension fabric roller minimizes the risk of fabric distortion or uneven application of the Epoxy solution, contributing to improved product reliability and manufacturing efficiency. Its intuitive design facilitates seamless integration into the manufacturing workflow, offering operators precise control over tension parameters to achieve optimal results in composite material fabrication.

[0033] The system incorporates a nail roller featuring a chuck mechanism designed for precise and rapid rolling of fabric using pin-sized nails. This gear-like chuck mechanism securely holds the fabric during the rolling process, ensuring consistent and secure attachment. The design facilitates efficient processing of fabric materials, minimizing handling errors and optimizing workflow efficiency. This feature is particularly beneficial in reducing manual labor and enhancing productivity in composite material manufacturing.

[0034] The chuck mechanism integrated into the nail roller of the composite material manufacturing system is designed to facilitate precise and efficient fabric rolling using pin-sized nails. Resembling a gear-like structure, the chuck mechanism securely holds the fabric in place during the rolling process, ensuring consistent and secure attachment throughout. This design not only enhances operational efficiency by minimizing fabric slippage but also reduces the need for manual adjustments, thereby streamlining the manufacturing process. The chuck mechanism's ability to maintain a firm grip on the fabric promotes uniformity in rolling, crucial for achieving consistent composite material quality. Its robust construction and reliable performance make it an essential component in optimizing workflow efficiency and product reliability within laboratory settings.

[0035] To streamline operations, the system includes a fan dryer system dedicated to efficiently drying cloth after immersion and before rolling with the nail roller. This component is equipped with adjustable airflow settings and temperature controls, allowing operators to optimize drying times based on specific manufacturing requirements. By ensuring thorough and rapid drying of fabric materials, the fan dryer system enhances overall manufacturing efficiency and productivity, thereby reducing processing time and energy consumption.

[0036] The fan dryer system in the composite material manufacturing setup is engineered to expedite the drying process of fabric after it has been immersed in the Epoxy-solution and before rolling with the nail roller. Featuring adjustable airflow settings and precise temperature controls, the fan dryer system efficiently removes moisture from the fabric while maintaining optimal drying conditions. By directing controlled airflow over the fabric surface, the system accelerates evaporation, significantly reducing drying times and enhancing overall manufacturing efficiency. This capability not only minimizes production delays but also conserves energy, making the manufacturing process more cost-effective. The fan dryer system's ability to quickly prepare fabric for subsequent processing steps ensures consistent product quality and reliability, contributing to streamlined operations in composite material fabrication.

[0037] Facilitating precise fabric processing, the system incorporates a programmable fabric cutter. This cutter is designed to deliver accurate cuts according to predetermined dimensions, accommodating customizable fabric shapes and sizes tailored to specific composite material applications. The programmable nature of the fabric cutter enhances flexibility in production, allowing for seamless integration into varying manufacturing processes. This feature supports the creation of tailored composite materials with precision and consistency, meeting diverse industry demands effectively.

[0038] The fabric cutter integrated into the composite material manufacturing system is a sophisticated tool designed to facilitate precise and customizable cutting of fabric materials. Utilizing programmable settings, the fabric cutter allows operators to specify dimensions and shapes according to the requirements of specific composite material applications. This flexibility enables tailored fabrication of composite components with accuracy and consistency, optimizing material usage and reducing waste. The cutter's automated operation enhances workflow efficiency by eliminating the need for manual cutting, thereby streamlining production processes in laboratory settings. Its precision cutting capabilities ensure clean edges and uniformity, essential for achieving high-quality composite materials. Overall, the fabric cutter represents a critical component in the system, supporting efficient and reliable manufacturing of composite materials while enhancing overall productivity and operational control.

[0039] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention.

, Claims:We Claim:
1) A composite material manufacturing system, comprising:
a) a removal soaking container configured as a drawer with curved sliding shapes for casing, the container being removable and constructed for longevity and convenience, wherein all sections of the container are detachable for maintenance;
b) a tension fabric roller with a spring-based mechanism system for creating customized tension distribution over fabric;
c) a nail roller with a chuck mechanism for precise and quick fabric rolling using pin-sized nails;
d) a fan dryer system for efficiently drying cloth before rolling with the nail roller, thereby preparing the fabric for subsequent processing steps; and
e) fabric cutter for providing precise cutting as needed, facilitating seamless and accurate fabric processing activities.
2) The system as claimed in claim 1, wherein said removal soaking container further includes mechanisms for automated immersion, straightening, and drying of cloth submerged in Epoxy solution, thereby reducing manual handling and exposure to harmful vapors.
3) The system as claimed in claim 1, wherein said tension fabric roller is adjustable to provide varying degrees of tension suitable for different types of fabrics, ensuring uniform tension distribution and enhancing overall composite material quality.
4) The system as claimed in claim 1, wherein said nail roller includes a gear-like chuck mechanism configured to securely hold and roll fabric using pin-sized nails, ensuring consistent and secure attachment of the fabric during processing.
5) The system as claimed in claim 1, wherein said fan dryer system includes adjustable airflow settings and temperature controls to optimize fabric drying times, thereby increasing manufacturing efficiency and productivity.
6) The system as claimed in claim 1, wherein said fabric cutter is programmable to provide precise cuts according to predetermined dimensions, allowing for customizable fabric shapes and sizes tailored to specific composite material applications.