Composite Monolithic Fabrication With Two-Stage Air-Free Curing
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Solution Overview
Problem
Current methods for fabricating composite monolithic structures incorporate air, which is detrimental to achieving high electrical or mechanical performance parameters, and involve complex process conditions, leading to poor reliability and premature failure under high stress applications.
Innovation Solution
The method involves coating an insulating layer with an uncured binding material, performing a first stage curing process to form a non-tacky binding material, and then disposing the insulating layer on an array of conductive structures. A second stage curing process is performed to form fully cured regions between adjacent conductive structures, effectively eliminating air pockets and enhancing bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current fabrication methods are used, then the process is simpler, but air is incorporated into the composite structure which deteriorates electrical and mechanical performance
Solution Approach 1:
The curing process is segmented into multiple stages: an initial curing stage followed by a final curing stage. This segmentation allows air to be removed during the initial stage while the resin maintains sufficient viscosity to prevent re-entrainment, and then allows complete curing in the final stage to achieve optimal mechanical properties without air pockets.
Solution Approach 2:
The initial curing stage performs a preliminary action by partially curing the resin before the structure is subjected to high stress or final assembly. This preliminary curing establishes a viscous state that prevents air entrapment while allowing subsequent complete curing to achieve full performance.
2Reliability
If current fabrication methods are used, then processing is faster, but the composite structure exhibits poor reliability under high stress
Solution Approach 1:
The curing process is divided into distinct stages with specific objectives: initial curing removes air and establishes viscosity control, while final curing achieves complete polymerization. This segmentation ensures air-free composite structures with optimal mechanical properties, preventing premature failure under high stress despite increased processing time.
Solution Approach 2:
The resin's physical and chemical parameters are dynamically controlled during different curing stages. During initial curing, temperature and time parameters are optimized to achieve a viscous state that prevents air entrapment. During final curing, parameters are adjusted to complete polymerization and achieve optimal mechanical strength for high stress applications.
3Ease of manufacture
If air is incorporated in the composite structure, then fabrication is easier, but electrical and mechanical performance parameters are deteriorated
Solution Approach 1:
The manufacturing process is segmented into initial curing and final curing stages. The initial curing stage creates a viscous resin state that prevents air entrapment during consolidation, while the final curing stage achieves complete polymerization. This segmentation simultaneously improves ease of manufacture by allowing controlled air removal and achieves manufacturing precision by eliminating air pockets that would deteriorate electrical and mechanical performance.
4Loss of time
If a single-stage curing process is used, then processing time is reduced, but air pockets remain in the composite structure
Solution Approach 1:
The curing process is segmented into two distinct stages: initial curing at controlled conditions to achieve a viscous state that prevents air entrapment, and final curing to complete polymerization. This segmentation ensures complete air removal and optimal composite structure integrity, accepting that total processing time is divided into two stages rather than one accelerated stage.
Solution Approach 2:
Curing parameters (temperature, time, pressure) are changed between stages. During initial curing, parameters are set to achieve a specific viscosity range that prevents air re-entrainment. During final curing, parameters are adjusted to complete the polymerization reaction and achieve optimal mechanical and electrical properties, ensuring air-free composite structures.
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 approach results in composite structures with improved reliability, higher performance, and lower life-cycle costs, while also simplifying the fabrication process with reduced processing time and costs.
Implementation Method 1
performing a first stage curing process on the uncured binding material to form a first stage cured binding material on the insulating layer
Implementation Method 2
performing a second stage curing process on the first stage cured binding material to form a second stage cured binding material
Data Source
AI summary
Fabricating composite monolithic structures to achieve optimal electrical, thermal, and mechanical properties through the elimination of air is discussed herein. A method of fabricating a composite structure includes coating an insulating layer with an uncured binding material and performing a first curing process on the uncured binding material to form a first stage cured binding material on the insulating layer without introduction of air pockets in a conventional manufacturing atmospheric environment. The method further includes disposing the insulating layer on an array of conductive structures. The first stage cured binding material is positioned between the insulating layer and the array of conductive structures. The method further includes performing a second curing process on the first stage cured binding material to form a cured binding material, and forming cured regions between adjacent conductive structures of the array of conductive structures.