Structural Composite Density via Cyclic Pressure Gas Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Structural polymeric composites often suffer from defects such as porosity and weakness due to trapped air and volatile gases during the curing process, leading to unpredictable mechanical characteristics.
Innovation Solution
A manufacturing system and method that applies varying pressure cycles to remove trapped air and volatile gases from the composite materials before the polymeric matrix fully cures, using a compression station with a control terminal to manage pressure signals and ensure efficient gas release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the composite mixture is compressed during curing, then the polymer liquid cures into a solid structure, but trapped air and volatile gases remain causing porosity and weakness
Solution Approach 1:
The patent applies preliminary action by implementing pressure cycles before the polymer fully cures to remove trapped air and volatile gases. The pressure cycles are applied during the curing process when the polymer is still in a semi-liquid state, allowing gases to escape before the final solid structure forms, thereby preventing porosity and weakness in the cured composite.
Solution Approach 2:
The patent employs periodic action through cyclic pressure application during the curing process. Multiple pressure cycles are applied at different stages of curing, with each cycle consisting of pressure application followed by release, allowing trapped gases to be progressively removed while the polymer transitions from liquid to solid state, resulting in a denser and stronger composite structure.
2Quantity of substance
If pressure is applied to remove trapped gases, then density increases, but the curing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by systematically varying pressure parameters during the curing process. Different pressure levels, cycle frequencies, and durations are used at different stages of curing to optimize gas removal while maintaining process control. The pressure cycles are adjusted based on the polymer's curing state, allowing effective density improvement without requiring overly complex equipment.
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 method effectively increases the density of structural composites by removing trapped gases, resulting in a stronger and more predictable mechanical structure.
Implementation Method 1
A first cyclic pressure is applied onto the composite mixture, for example, by using a second surface to compress toward the first surface. The cyclic pressure is for releasing trapped air and volatile gases from the composite mixture
Implementation Method 2
The polymeric composites are bonded in polymeric matrices formed from a polymer binder such as epoxy, acrylic, or other types or resin or curable materials solidified under thermal or polymerization processes
Implementation Method 3
curable materials solidified under thermal or polymerization processes
Data Source
AI summary
In one embodiment, a method for making a high density structural composite includes depositing a plurality of fibrous materials on or adjacent a first plate or surface. A polymer liquid is deposited onto the plurality of fibrous materials to form a composite mixture. A first cyclic pressure is applied onto the composite mixture to compress the composite mixture. In some embodiments, the cyclic pressure may then be reduced to a valley pressure to complete a pressurization cycle. In some instances, the valley pressure may be below atmospheric pressure to induce trapped air and volatile gases to escape from the composite mixture before curing. The pressurization cycle may be repeated. A second pressure, which may be a constant pressure in some embodiments, may be applied to the composite mixture using, in some embodiments, a second plate until the polymer liquid has at least partially cured or partially solidified.