Subproject B1: Making-up processes in the assembly of textile components, spacer structures, selvedge structures and inserts

Supervision
Prof. Dr.-Ing. habil. Hartmut Rödel
TU Dresden
Institute of Textile Machinery and High Performance Material Technology
01062 Dresden
Germany
Phone: +49 351 463-39313
Fax: +49 351 463-39301

Prof. Dr. rer. nat. habil. Gert Heinrich
Leibniz Institute of Polymer Research Dresden
Hohe Str. 6
01069 Dresden
Tel.: +49 351 4658-361
Fax: +49 351 4658-362



Abstract
Thermoplastic hybrid structures are used to develop and test making-up processes (CAD, cutting, piling, assembly) for the manufacture of textile spacer preforms.

Making-up techniques allow the fabrication of large-size spacer preforms and complex component designs. In the first project phase from 2004 to 2007, mainly flat spacer preforms were developed and manufactured. Since the assembly procedure for textile spacer preforms definitely had a novelty value, it was protected by patent. Programs for CNC-controlled sewing machines have been developed and sewing techniques have been tested with the aim to integrate inserts.

To continue this research (interconnection phase), it is necessary to develop and test curved spacer preforms, manufactured on the basis of making-up processes, taking account of process safety, quality assurance and reproducibility. These curved spacer preforms have strengthening trusses and webs, force introduction zones and sensory properties.

The essential steps are listed below:

• shape- and load-oriented pattern generation of various textile semi finished products from the industry and other subprojects
• design and construction of tools for staple holders for the manufacture of these singly curved spacer preforms
• stiffness-enhancing trusses and webs and force introduction zones thanks to inserts
• integration of functionalised hybrid yarns with sensory properties (from subproject A2) during the making-up process
• introduction of sensor networks focussing on contacting on the basis of making-up processes and CAD design of the sensor network geometry.

Drawing upon the results and findings of the fabrication of singly curved spacer preforms, the conceptual development of doubly curved spacer preforms is begun. This task makes high demands on the making-up process of manufacturing. Thanks to the close co-operation in the Collaborative Research Centre (SFB), in particular with subprojects D4 and E1 focussing on design and production, the processes developed in the SFB are finally brought together in the 3rd phase.