Arch-Shaped Edge Breather for Composite Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The composite vacuum bag manufacturing process faces challenges in designing breathers that can effectively manage air and volatile gases while withstanding high pressures and heat without increasing costs or compromising quality.
Innovation Solution
The introduction of truss-like edge breathers made from rigid materials with arch-shaped cross sections and hollow passageways, which allow air to flow freely and can bear loads up to 90 PSI, preventing damage to the vacuum bag during the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional solid breathers are used, then structural strength is sufficient, but air and volatile gases cannot flow efficiently through them
Solution Approach 1:
The breather is designed with a porous or open-cell foam structure that allows gas to flow through while maintaining structural integrity. This porous architecture enables volatile compounds and air to pass through the breather during vacuum bagging, resolving the contradiction between gas removal efficiency and structural strength.
Solution Approach 2:
The breather utilizes composite material structures, such as open-cell foam or cellular materials, that combine the properties of porosity for gas flow with sufficient mechanical strength to maintain structural integrity under vacuum pressure.
2Strength
If rigid solid breathers are used, then they can bear vacuum pressure, but they may damage the vacuum bag under high pressure
Solution Approach 1:
The breather incorporates flexible or compliant surfaces that can deform under high vacuum pressure (up to 90 PSI) without transmitting excessive point loads to the vacuum bag. This flexibility allows the breather to maintain pressure bearing capacity while preventing damage to the vacuum bag through stress distribution and deformation absorption.
3Ease of manufacture
If simple breather designs are used, then manufacturing cost is low, but they cannot withstand high vacuum pressure
Solution Approach 1:
Porous or open-cell foam breathers can be manufactured through relatively simple processes such as foam extrusion or molding, achieving both ease of manufacture and sufficient strength to withstand high vacuum pressures through the inherent cellular structure that distributes applied loads.
4Strength
If dense solid breathers are used, then structural integrity is maintained, but air flow through the breather is restricted
Solution Approach 1:
The porous structure provides interconnected voids and channels that facilitate gas flow while the solid struts or cell walls maintain structural integrity. The porosity allows high gas flow rates for efficient volatile removal, while the remaining solid material provides sufficient strength to withstand vacuum pressures.
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
These enhanced edge breathers ensure efficient removal of air and volatile gases, prevent air bubbles, and maintain the shape of composite parts under high pressure and heat, improving the quality and reducing the risk of vacuum bag rupture.
Implementation Method 1
Hollow passageways within the elongated body are underneath the top structure and travel along a length of the elongated body
Implementation Method 2
The vacuum bag applies pressure to contour and consolidate the layers against the surface of a working tool
Implementation Method 3
bearing load from a vacuum bag during curing of a product (e.g., at 90 pounds per square inch (PSI), in an autoclave)
Implementation Method 4
drawn a vacuum in the vacuum chamber, and drawing gases from the composite charge past a support member protruding from a base of the edge breathers
Data Source
AI summary
Systems and methods are provided for curing composite products. One exemplary embodiment is an edge breather for composite manufacturing. The edge breather is formed of a rigid material and includes an elongated body having a top open structure with a cross section that defines an arch. The edge breather also includes hollow passageways within the elongated body that are underneath the top structure and travel along a length of the elongated body. The top open structure defines multiple openings forming an open mesh through which air may enter.