Composite Duct Resin Impregnation via Segmented Barrier
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing graphite epoxy composite fan ducts and fan cases face challenges such as complex and expensive tooling, high porosity, microcracking, delamination, and difficulty in achieving uniform fiber orientation and resin distribution, leading to reduced mechanical properties and increased production time.
Innovation Solution
A method and tool that apply preselected amounts of matrix material to a fibrous composite preform, using a barrier material to direct resin flow and applying thermal expansion differences to pull the fibers taut, while reducing internal pressure and increasing external pressure to achieve uniform matrix distribution and low void content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If full coverage of resin layers is applied onto the entire surface of the reinforcing fiber preform, then the preform is completely impregnated, but air and gases are entrapped forming voids and porosity
Solution Approach 1:
The preform surface is divided into multiple zones with different resin application densities. High-density zones are placed in regions prone to void formation (corners, edges, complex geometries), while low-density zones are applied in simpler areas. This segmented approach ensures complete impregnation without over-saturation that would trap air.
Solution Approach 2:
Different resin layer densities are applied to different locations on the preform based on local impregnation needs. The system adjusts resin flow characteristics and layer thickness locally to match the specific geometric and absorption requirements of each region, preventing air entrapment while ensuring thorough impregnation.
2Manufacturing precision
If complex tooling systems are used to manufacture composite fan ducts, then fiber orientation and resin distribution can be controlled, but the manufacturing cost and process complexity increase
Solution Approach 1:
The system uses the preform's own geometry and the natural flow characteristics of resin under applied pressure to achieve proper fiber orientation and resin distribution. Simple fixtures and pressure application mechanisms replace complex multi-component tooling systems, as the process leverages the material's inherent properties rather than requiring elaborate external control structures.
Solution Approach 2:
The system controls resin impregnation by adjusting parameters such as pressure, temperature, and resin viscosity rather than relying on complex mechanical tooling. By changing these process parameters dynamically, the system achieves precise fiber orientation and resin distribution with simpler equipment.
3Ease of manufacture
If traditional composite manufacturing methods are used, then production can proceed with existing equipment, but porosity and microcracking reduce mechanical properties
Solution Approach 1:
The system applies resin to the preform before final consolidation, allowing the resin to penetrate and impregnate the fiber structure in advance. This preliminary impregnation action ensures thorough saturation before the part is cured, preventing void formation and microcracking that would otherwise reduce mechanical properties, while using equipment similar to existing manufacturing setups.
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 results in high-strength, lightweight composite containment ducts with reduced porosity and defects, requiring less trimming and assembly, suitable for large parts like fan casings, and capable of containing fan blades during operation.
Implementation Method 1
applying thermal expansion differences to pull the fibers taut
Implementation Method 2
reducing internal pressure and increasing external pressure to achieve uniform matrix distribution
Data Source
AI summary
A reinforced matrix composite containment duct for gas turbine engines comprising a reinforced matrix composite containment duct having high strength integral flanges and pre-stressed reinforcing fibers, the reinforced matrix composite having uniform distribution of matrix material; and the reinforced matrix composite having less than or equal to 2.5% void space.