Co-cured Short-Fiber Resin Damping Composite Molding
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Solution Overview
Problem
Current resin-based composite materials processed by centrifugal molding have poor vibration reduction and sound absorption performance, failing to meet the increasing demands for high dynamic performance in aerospace applications due to their single-layer, thin-walled structure.
Innovation Solution
A centrifugal molding process involving a three-layer structure of high-density short-fiber resin, a damping layer, and low-density short-fiber resin, where materials with specific densities are co-cured using a controlled pouring speed and temperature to achieve uniform distribution and enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer structure with one kind of resin is used, then the manufacturing process is simple, but the vibration reduction and sound absorption performance is poor
Solution Approach 1:
The patent applies composite materials by combining three different resin systems (high-density epoxy resin, damping rubber, and low-density polyester resin) with short fibers to create a multi-layer composite structure. This composite approach enables the thin-walled tube to simultaneously achieve structural strength, vibration damping, and sound absorption, resolving the contradiction between manufacturing simplicity and performance requirements.
Solution Approach 2:
The patent segments the single-layer structure into three distinct layers with different functions: an outer high-density epoxy resin layer for structural strength, a middle damping rubber layer for vibration reduction, and an inner low-density polyester resin layer for sound absorption. This segmentation allows each layer to optimize its specific function while working together as an integrated system.
2Reliability
If a multi-layer co-cured structure is used, then the vibration reduction and sound absorption performance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges three separate resin pouring operations into a single co-curing process. By sequentially pouring the high-density epoxy resin, damping rubber, and low-density polyester resin into the mold cavity and then applying heat and pressure simultaneously, all three layers are cured together in one operation. This merging approach reduces the number of separate manufacturing steps and simplifies the overall process despite the multi-layer complexity.
Solution Approach 2:
The patent applies preliminary action by pre-heating the mold cavity before pouring the resins and pre-mixing each resin system with short fibers in advance. These preliminary preparations ensure that when the resins are poured and cured together, they flow and bond properly without requiring additional processing steps, thereby reducing overall process complexity.
3Strength
If high-density resin is used, then the structural strength is improved, but the vibration damping performance is reduced
Solution Approach 1:
The patent applies local quality by assigning different material properties to different regions of the thin-walled tube structure. The outer layer uses high-density epoxy resin with high structural strength but lower damping, while the middle layer uses damping rubber with high vibration damping properties. Each layer's material properties are optimized for its specific location and function, allowing the overall structure to achieve both strength and damping performance.
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
The resulting composite material exhibits a firmer structure with improved vibration reduction and sound absorption performance, meeting higher technical requirements compared to single-layer materials.
Implementation Method 1
centrifugal molding process
Implementation Method 2
preheating a die cavity wall of the mold so that moisture in the paint is sufficiently evaporated
Implementation Method 3
pressurizing and heating the die cavity of the mold so that the materials are co-cured
Data Source
AI summary
A molding process of a co-cured short-fiber resin-based damping composite material and a molding part. Different from a traditional centrifugal processing process of a thin-walled tube of a resin-based composite material, the process uses raw materials including three kinds of materials with different densities and including two kinds of short-fiber epoxy resin with different densities and a damping material. During centrifugal molding, the three kinds of materials are made into fluids to be respectively injected at a uniform speed in three times according to the sizes of the densities. Layering is performed by using different centrifugal forces applied to the three kinds of materials. Co-curing is performed according to a resin curing process after the three kinds of materials are stably distributed, and a tubular thin-walled part of the embedded co-cured short-fiber resin-based damping composite material with a uniform wall thickness is obtained.