Actuatable Flow Media for Uniform Resin Infusion Control
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Solution Overview
Problem
Current resin infusion methods for composite structures face challenges in ensuring uniform resin flow across complex preform geometries, leading to incomplete infusion and deficient composite components, particularly due to the mechanical nature of resin inlet valves and the use of consumable flow media which can be time-consuming and laborious.
Innovation Solution
An elastically deformable actuatable flow media system with a base and flexible membrane, featuring apertures and elastically deformable elements that can be actuated to control resin flow rates by selectively opening or closing liquid pathways, allowing for precise regulation of resin infusion into composite preforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical resin inlet valve is used to control resin flow rate, then the flow rate can be controlled, but the valve becomes filled with resin and requires time-consuming disassembly and cleaning between uses
Solution Approach 1:
The patent employs a consumable flow media (permeable fabric or mesh) that is discarded after a single use. This eliminates the need to clean and maintain mechanical valves, as the flow control function is performed by the disposable permeable material that is replaced rather than reused.
Solution Approach 2:
The invention extracts the flow control function from the mechanical valve system and transfers it to the permeable flow media. The valve is removed from the resin supply pipe, and flow rate control is achieved through the permeability characteristics of the consumable fabric or mesh material instead.
2Reliability
If consumable flow media is placed on the peel ply to promote resin flow, then resin flow through all sections of the preform is improved, but the approach is not successful for complex preform geometries and requires laborious application
Solution Approach 1:
The permeable flow media serves multiple functions simultaneously: it acts as a flow distributor to ensure uniform resin flow, a flow rate controller to regulate infusion speed, and a geometry-adapted layer that conforms to complex preform shapes. This multi-functionality eliminates the need for separate components and simplifies the overall infusion system.
3Productivity
If resin infusion is performed without flow control, then the process is simpler, but the resin wavefront does not progress evenly and incomplete infusion occurs in less permeable areas
Solution Approach 1:
The permeable flow media is positioned strategically at the resin inlet to provide localized flow control. The media's permeability characteristics create a distributed flow pattern that ensures resin progresses evenly across the preform surface, preventing starvation of less permeable areas while maintaining overall infusion speed.
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
This solution enables controlled resin infusion, ensuring complete saturation of composite preforms, reducing labor and equipment costs by eliminating the need for mechanical resin inlet valves and improving the consistency of composite components.
Implementation Method 1
an elastically deformable element arranged in each base cavity and extending between the base and the flexible membrane for actuation between at least a first configuration, in which each elastically deformable element is substantially undeformed and the first and second liquid flow paths are open, and a second configuration in which each elastically deformable element is substantially deformed and at least one of the first and second liquid flow paths is closed
Implementation Method 2
Resin is infused through the composite preform by application of vacuum pressure to a downstream end of the sealed chamber, drawing resin from an upstream resin supply through the composite preform
Data Source
AI summary
An actuatable flow media for controlling a flow rate of a liquid through the flow media, the actuatable flow media comprising a base having a plurality of base cavities formed therein, at least one aperture formed in each base cavity defining a liquid flow path for the entry of liquid into or exit of liquid from the flow media; a flexible membrane arranged in spaced relation with the base and defining a liquid flow path through the flow media; and an elastically deformable element arranged in each base cavity and extending between the base and the flexible membrane for actuation between at least a first configuration in which the element is substantially undeformed and the liquid flow path through the at least one aperture is open and a second configuration in which the element is substantially deformed and the liquid flow path through the at least one aperture is closed.