Composite Molding Core for Recyclable Hollow OMC Parts
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Solution Overview
Problem
Current methods for manufacturing OMC hollow aeronautical parts face challenges such as the need for complex and costly tooling, environmental hazards from core dissolution, degradation of mechanical properties due to temperature changes, and limited machinability of molding cores.
Innovation Solution
A composite material comprising a first phase of Mn+1AlCn (M being Ti, Nb, Cr, or Zr) and a second phase of Al4C3 is used for the molding core, which allows for easy knockout and recycling, while maintaining mechanical strength and thermal stability, using a powder metallurgy process and hydrolysis for core removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If soluble cores are used for manufacturing OMC parts, then core removal is simplified, but environmental pollution occurs and core recycling is impossible
Solution Approach 1:
The patent changes the chemical composition parameters of the molding core by using MAX phase materials (Ti3AlC2, Ti2AlC, Cr2AlC, Zr2AlC, Nb4AlC3, or Nb2AlC) which have controlled solubility in the resin matrix. These materials are designed to dissolve selectively at specific temperatures and times, enabling easy core removal while allowing the dissolved material to be filtered and recycled, thus resolving the contradiction between ease of manufacture and environmental harm.
Solution Approach 2:
The patent employs composite material structures where the MAX phase materials are combined with fibrous reinforcements (such as carbon fibers, glass fibers, or ceramic fibers). This composite approach allows the core to maintain structural integrity during manufacturing while enabling controlled dissolution later, facilitating both easy removal and potential recycling of the dissolved phase, thereby addressing both ease of manufacture and environmental concerns.
2Ease of manufacture
If temperature rise is applied to dissolve cores, then core removal is achieved, but mechanical properties of OMC composite material are degraded
Solution Approach 1:
The patent utilizes the temperature-dependent solubility parameters of MAX phase materials to enable core removal. These materials are selected because they dissolve at relatively low temperatures (below the degradation temperature of the OMC composite), allowing core removal through controlled heating that does not compromise the mechanical properties of the final composite structure.
Solution Approach 2:
The patent employs MAX phase materials as temporary, disposable core structures that are designed to be removed after serving their molding function. These materials can be dissolved under controlled conditions and potentially recycled, representing a cost-effective and environmentally friendly alternative to permanent core structures, while avoiding the need for high-temperature processing that would degrade the composite material.
3Weight of moving object
If complex hollow structures are manufactured, then weight savings are increased, but device complexity increases
Solution Approach 1:
The patent applies local quality by using fibrous reinforcements (such as 3D interlock weaves, braids, or winds) that are strategically placed within the preform to create complex hollow structures. The MAX phase materials serve as temporary cores with specific geometric configurations that define the desired hollow shapes. This localized approach allows complex geometries to be achieved without requiring complex tooling, as the fiber architecture itself creates the structural complexity.
Solution Approach 2:
The patent employs segmentation by dividing the composite structure into fibrous reinforcement phases and MAX phase material cores. The fibrous reinforcements are arranged in specific patterns (3D interlock, braiding, winding) to create segmented hollow structures that provide both weight savings and structural integrity. The MAX phase cores are segmented into manageable shapes that can be easily inserted and later removed, reducing overall device complexity.
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
Enables the production of complex hollow structures with efficient core removal, avoiding harmful chemicals and environmental impact, and allowing for core recycling.
Implementation Method 1
Al4C3, which facilitates the knockout of the molding core by its reactivity towards water-containing atmospheres
Implementation Method 2
a shaping step, in particular by injection molding, and a sintering step
Data Source
AI summary
Molding core for manufacturing an OMC hollow aeronautical part, in particular a fan module part, including a composite material including on the one hand a first phase of formula Mn+1AlCn, where n=1 to 3, and M being a transition metal selected from the group consisting of titanium, niobium, chromium or zirconium, the composite material including on the other hand a second phase of formula Al4C3.