Composite Co-Curing Process Using Intermediate Substrates
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Solution Overview
Problem
Current manufacturing processes for composite material monocoques in the automotive industry are costly and lack repeatability due to high manual intervention, complex systems, and limited mold life, making mass production challenging and prone to production stops and rejects.
Innovation Solution
A process and system that incorporates co-curing of components with intermediate substrates, using modular moulds and processes like RTM and braiding, which reduces mold complexity, increases repeatability, and allows for parallel production steps, thereby lowering costs and improving structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual stratification and separate moulding of components is used, then manufacturing flexibility is maintained, but production cost increases and repeatability decreases
Solution Approach 1:
The patent combines multiple separate moulding operations into a single automated moulding process that produces multiple components simultaneously, eliminating manual stratification and assembly operations while improving repeatability and reducing costs
2Adaptability or versatility
If numerous separate components are moulded and assembled, then design flexibility is achieved, but production complexity and cost increase
Solution Approach 1:
The patent segments the moulding process into modular zones within a single mould assembly, allowing different components to be moulded independently in different zones while maintaining overall process integration and simplicity
3Strength
If pre-preg materials are used with manual layering, then material properties are optimized, but production time and cost increase
Solution Approach 1:
The patent replaces manual mechanical layering operations with an automated material delivery system that deposits reinforcement material in a controlled manner, maintaining material property optimization while dramatically reducing production time and labor requirements
4Manufacturing precision
If multiple moulds are reserved for single component production, then component quality is maintained, but system complexity and cost increase
Solution Approach 1:
The patent designs a universal mould assembly that can simultaneously produce multiple different components with high precision, replacing the need for multiple dedicated moulds and reducing overall system complexity while maintaining component quality
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 significantly reduces production costs, enhances repeatability, extends mold life, and minimizes the risk of production errors and rejects, enabling more efficient and cost-effective mass production of composite material products like vehicle shells and roofs.
Implementation Method 1
The intermediate substrates are then pressed on the main component by means of a vacuum bag, after which at least one adhesive layer is preferably arranged on the intermediate substrates. The secondary components are then arranged on the intermediate substrates and/or on the main component
Implementation Method 2
The intermediate substrates are then pressed on the main component by means of a vacuum bag
Implementation Method 3
after which at least one adhesive layer is preferably arranged on the intermediate substrates. The secondary components are then arranged on the intermediate substrates and/or on the main component
Data Source
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AI summary
Process for manufacturing composite material products (44, 48, 52), which process comprises at least the following operating steps: - moulding at least one main component (18) made of a composite material and one or more secondary components (19, 20, 21, 22) made of a composite material by means of one or more main moulds (11, 13) and one or more secondary moulds (23, 24, 25, 26), respectively; arranging one or more intermediate substrates (41) of fibers, in particular carbon fibers, pre-impregnated with a resin, between said main component (18) and/or said secondary components (19, 20, 21, 22) in a moulding assembly (40) comprising at least one main mould (11; 31) and/or one or more secondary moulds (23, 24, 25, 26; 35, 36, 37, 38, 39); curing the resin of said intermediate substrates (41) in the moulding assembly (40), so that the main component (18) and the secondary components (19, 20, 21, 22) are joined to each other through the intermediate substrates (41). The present invention also relates to a system which can be used in such process, as well as the products manufactured with this process and/or system.