Compaction Tool for Female Mold Composite Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Composite materials manufactured using female tools often suffer from defects such as bridging and resin richness at transition areas and internal radii, which compromise the structural integrity and require reworking or scrapping of parts, and existing vacuum bagging processes are slow, limiting production rates.
Innovation Solution
A tooling system with a compaction tool featuring axially movable pressing devices that apply sequential pressure to fiber-reinforced resin parts on a female mold surface, ensuring proper compaction of fibers at transition regions and shoulder areas to prevent bridging and resin richness, using expandable members and actuation devices to maintain pressure for controlled dwell times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum bagging process is used to prevent bridging and resin richness, then manufacturing precision is improved, but productivity deteriorates due to extremely slow process speed
Solution Approach 1:
The pressing member is divided into multiple independent pressing zones (first pressing zone for transition regions, second pressing zone for shoulder regions) that can operate independently or simultaneously, enabling targeted compaction without requiring slow vacuum bagging while maintaining high fiber density uniformity
Solution Approach 2:
The pressing member is designed to be movable and adjustable, allowing dynamic positioning and application of pressure to different mold surface regions as needed, replacing the static and slow vacuum bagging process with a controllable mechanical pressing system that maintains precision while increasing speed
2Adaptability or versatility
If female tools are used for manufacturing, then adaptability is improved for various part shapes, but manufacturing precision deteriorates due to bridging and resin richness at transition areas
Solution Approach 1:
The pressing member provides different pressing characteristics for different mold surface regions - transition regions receive pressing from the first pressing zone while shoulder regions receive pressing from the second pressing zone, allowing each area to be optimized for its specific geometric requirements while maintaining overall fiber density uniformity
Solution Approach 2:
The pressing member is positioned and adjusted before the composite material is laid up on the mold surface, allowing preliminary compaction and prevention of bridging and resin richness issues before they occur during the manufacturing process
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 system effectively prevents bridging and resin richness, maintaining fiber density and structural integrity, while significantly increasing production efficiency by reducing the need for reworking and scrapping, and allowing for rapid installation and use of multiple compaction tools.
Implementation Method 1
A compaction tool including a first pressing device and a second pressing device carrying the first pressing device is positioned over the mold surface. The first pressing device is axially movable relative to and independent of the second pressing device. Pressing a first portion of the fibers against the transition regions of the mold surface with the first pressing device
Implementation Method 2
maintaining the pressure on the first portion of the fibers for a first dwell time before pressing the second portion of the fibers, and maintaining the pressure on the second portion of the fibers for a second dwell time
Data Source
AI summary
Tools for manufacturing composite parts and methods for using such tools are disclosed herein. A method in accordance with one aspect of the invention includes manufacturing a fiber-reinforced resin part from a plurality of fibers positioned on a tool having a female mold surface. The mold surface can include a first side region, a second side region, an interior region between the first and second side regions, and transition regions between the first and second side regions and the interior region. The method includes positioning a compaction tool over the mold surface. The compaction tool includes a first pressing device and a second pressing device carrying the first pressing device. The method further includes pressing a first portion of the fibers against the transition regions with the first pressing device without generally compacting the portions of the fibers outboard of the transition regions. After pressing the first portion of the fibers, the method includes pressing a second portion of the fibers against the first and second side regions and shoulder regions of the mold surface outboard of the first and second side regions.