Composite Fabric Weave Regularity in Resin Transfer Molding
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Solution Overview
Problem
Existing methods for producing composite materials with carbon fibre fabrics, such as RTM and RTM-L, suffer from fibre displacement during resin injection, leading to irregular weave and poor aesthetic quality, while prepreg methods offer better aesthetics but at higher costs and compromised structural properties.
Innovation Solution
A method using dry fibre fabrics with a layer of non-polymerized resin and a thermoplastic film applied between the fabric and structural layers, which adheres to the mould and is impregnated with resin and hardener, ensuring regular weave and high structural integrity, combined with a semi-finished item that can be easily cut and stored.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If RTM or RTM-L method is used to produce composite parts from dry fabric layers, then production time is reduced and structural properties are improved, but fibre displacement occurs during resin injection causing irregular weave and poor aesthetic quality
Solution Approach 1:
The patent applies a preliminary action by placing a release agent on the mould surface before injecting the resin. This preparatory step creates a controlled interface that prevents fibre displacement during resin injection, allowing the outer fabric layer to maintain its weave regularity while still enabling efficient RTM production
Solution Approach 2:
The release agent acts as an intermediary substance between the mould surface and the resin-fabric system. It mediates the interaction by providing a controlled interface that reduces friction and prevents fibre displacement, thereby maintaining weave regularity during the resin injection process
2Manufacturing precision
If prepreg method is used to maintain weave regularity and aesthetic quality, then aesthetic appearance is improved, but production cost increases and structural properties are compromised
Solution Approach 1:
The patent employs a disposable release agent applied to the mould surface that is inexpensive and single-use. This allows the process to achieve prepreg-level aesthetic quality through maintained weave regularity, while avoiding the high costs associated with prepreg materials and their complex storage and handling requirements
3Manufacturing precision
If prepreg method is used to maintain weave regularity, then aesthetic quality is improved, but structural properties of the composite product deteriorate
Solution Approach 1:
The patent applies local quality by using a release agent specifically at the mould-fabric interface where fibre displacement occurs. This localized intervention maintains weave regularity and aesthetic quality at the surface, while the bulk structural layers can be optimized for mechanical properties through proper resin impregnation and curing
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 achieves high aesthetic quality and structural integrity, comparable to prepreg methods, while reducing production time and costs, by maintaining fibre regularity and improving bond strength between layers during resin injection.
Implementation Method 1
a layer of non-polymerized resin which causes the outer fabric layer to adhere to a functional surface of the mould
Implementation Method 2
a hardener which is sufficient in quantity to also polymerize the resin applied on the fabric layer
Implementation Method 3
Thanks also to a thermoplastic film applied between the fabric layer and a structural layer adjacent thereto, the fabric layer is held more securely in the correct position during resin injection
Data Source
AI summary
A method for producing products made of composite material, including the following operating steps: placing between a first mould and at least a second mould at least one layer of composite material fibre fabric and at least a first layer of composite material fibres, wherein a layer of non-polymerized, composite material resin, substantially free of hardener, is placed between the fabric layer and the first mould; injecting resin and hardener between the first mould and the second mould to impregnate the layer and the first fibre layer with the injected resin and polymerizing the injected resin and the resin layer with the injected hardener. A semi-finished item which can be used in this method and to a product made using this method and/or with this semi-finished item.