Bulk Resin Infusion Pressure Control
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Solution Overview
Problem
The existing resin infusion systems in the aerospace industry struggle to control the pressure and rate of resin infusion independently of compaction pressure on the reinforcement, limiting the use of higher viscosity resins and potentially causing voids or imperfections due to outgassing.
Innovation Solution
A method involving bulk resin infusion where a pressure differential is created outside the bagging film over the resin zone to control the infusion rate and pressure, while heating the resin to reduce viscosity and using a vacuum to prevent outgassing, allowing for independent control of resin infusion parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a pressure differential is applied across the envelope to cause resin flow, then resin infusion rate increases, but compaction pressure on the reinforcement cannot be controlled independently
Solution Approach 1:
The system divides the pressure control into two independent segments: (1) compaction pressure control through the bagging film applied to the reinforcement, and (2) resin pressure control through the pressure differential applied across the envelope. This segmentation allows independent adjustment of each parameter without affecting the other, resolving the contradiction between infusion rate and control independence.
Solution Approach 2:
The bagging film acts as an intermediary element that transmits compaction pressure to the reinforcement while being permeable to resin flow. This intermediary allows the resin to flow through the film under pressure differential while the film itself provides the compaction force, enabling independent control of the two pressure parameters.
2Manufacturing precision
If liquid resin is injected through tubing into the bagged reinforcement, then resin distribution is controlled, but system complexity increases and vacuum leak sources are introduced
Solution Approach 1:
The invention extracts and eliminates the complex tubing system from the resin infusion process. Instead of injecting resin through tubing, the system places resin directly in the bagged reinforcement and applies a pressure differential across the entire envelope, allowing resin to flow naturally from the placement location throughout the reinforcement without requiring injection tubing.
Solution Approach 2:
The resin infusion process becomes self-service by utilizing the pressure differential across the envelope to automatically distribute resin throughout the reinforcement. The system does not require external injection mechanisms or tubing to force resin into the reinforcement; the pressure gradient itself drives the resin flow and distribution.
3Speed
If compaction pressure is applied to cause resin flow, then infusion rate increases, but resin pressure cannot be controlled independently of compaction pressure
Solution Approach 1:
The pressure control system is segmented into two independent control mechanisms: compaction pressure applied through the bagging film and resin pressure controlled by the pressure differential across the envelope. This segmentation enables precise independent measurement and control of each pressure parameter, resolving the contradiction between flow speed and measurement precision.
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 method enables precise control of resin infusion, preventing voids and allowing the use of higher viscosity resins, ensuring consistent and efficient infusion processes, even with thermoset resins, thereby enhancing the quality and reliability of composite structures.
Implementation Method 1
heating the resin while applying compaction pressure to the bagging film to cause the resin to be infused into the reinforcement
Implementation Method 2
creating a pressure differential outside of the bagging film over the resin zone to control rate and pressure at which the resin is infused into the reinforcement
Implementation Method 3
using a vacuum to prevent outgassing
Data Source
AI summary
A method for performing resin infusion into a dry reinforcement on a layup mandrel comprises placing resin at a resin zone on the mandrel; bagging the reinforcement and the resin with a bagging film; heating the resin while applying compaction pressure to the bagging film to cause the resin to be infused into the reinforcement; and creating a pressure differential outside of the bagging film over the resin zone to control rate and pressure at which the resin is infused into the reinforcement. As a result, the resin pressure and infusion rate are controlled independently of the compaction pressure on the reinforcement.