Fiber-Reinforced Composite Curing by Metal Extrusion Contraction
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Solution Overview
Problem
The manufacture of fiber-reinforced composite parts is energy intensive due to the need for heat and pressure to consolidate fibers and matrices, which poses inefficiencies in the manufacturing process.
Innovation Solution
A method involving extruding a hollow metal shape onto a fiber-reinforced preform at an extrusion temperature, cooling it to apply heat and consolidation pressure through thermal contraction, thereby curing the preform without the need for external pressure sources in some cases, and using a die to apply pressure in others.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If external heat and pressure are applied to consolidate fiber-reinforced preforms, then curing and consolidation are achieved, but energy consumption increases
Solution Approach 1:
The mold itself generates the heat required for curing through its own thermal energy, eliminating the need for external heating systems. The mold acts as both the forming tool and the heat source, allowing the composite part to cure within the mold during the forming process itself.
Solution Approach 2:
The process utilizes changes in temperature and pressure parameters during mold formation. As the mold cools and contracts, it automatically applies both thermal energy transfer and mechanical pressure to the preform, achieving curing and consolidation through natural parameter changes rather than sustained external energy input.
2Device complexity
If thermal contraction of the mold is used to apply consolidation pressure, then external pressure sources are eliminated, but control over pressure application becomes more dependent on material properties
Solution Approach 1:
The mold utilizes thermal contraction as it cools from forming temperature to ambient temperature. This thermal contraction automatically generates the consolidation pressure needed to densify the composite part. The pressure application is directly coupled to the temperature change, creating a self-regulating system where the mold's dimensional changes provide the necessary compaction force.
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 method reduces energy consumption by leveraging thermal contraction to cure the composite parts efficiently, while also allowing for the formation of both solid and hollow composite parts with precise control over dimensions and material properties.
Implementation Method 1
heat from the hollow metal shape is conducted into the fiber-reinforced preform for curing thereof
Implementation Method 2
a consolidation pressure for curing the fiber-reinforced preform is applied thereto via thermal contraction of the hollow metal shape onto the fiber-reinforced preform as it cools
Data Source
AI summary
A method of forming a fiber-reinforced composite part includes forming a composite preform by extruding a hollow metal shape onto a fiber-reinforced preform at an extrusion temperature and cooling the hollow metal shape from the extrusion temperature to a temperature less than the extrusion temperature. Heat from the hollow metal shape cooling from the extrusion temperature is conducted into the fiber-reinforced preform for curing thereof. Also, thermal contraction of the hollow metal shape onto the fiber-reinforced preform applies a consolidation pressure on the fiber-reinforced preform for curing thereof. The fiber-reinforced preform may be a hollow fiber-reinforced preform and a die can be moved through the hollow fiber-reinforced preform such that consolidation pressure is applied thereto by a combination of the thermal contraction of the hollow metal shape onto the hollow fiber-reinforced preform and the die moving through the hollow fiber-reinforced preform.