Composite Force-Insertion Interface Manufacturing

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Solution Overview

Problem

Composite material parts used in applications like aircraft engine nacelles and ram supports have weak areas at the connection interface between subassemblies, particularly under peeling forces due to high resin content and low fiber density, leading to reduced mechanical resistance.

Innovation Solution

A method involving pre-compacting a mixture of discontinuous long fibers with a thermosetting resin to form a preform, pre-curing it, and then combining it with a preform of continuous fibers impregnated with another thermosetting resin for polymerization, creating a composite material with a homogeneous interface that enhances mechanical resistance by eliminating resin-rich areas lacking fibers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If continuous fibers are used to construct the main body, then the part has good resistance to in-plane loads, but the connection interface has weak areas with high resin content and low fiber density that reduce resistance to peeling forces

Engineering Contradiction:

Improveresistance to in-plane loadsVSAvoidresistance to peeling forces at connection interface

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies local quality by using discontinuous long fibers specifically in the connection interface portion (force-insertion portion) while maintaining continuous fibers in the main body. This localized fiber type change ensures high fiber density and homogeneous resin distribution at the connection interface, eliminating weak areas while preserving the structural integrity of the main body.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining discontinuous long fibers with thermosetting resin in the connection interface portion, creating a locally optimized composite structure. This composite approach allows the connection interface to have different material properties than the main body, specifically higher fiber density and better resistance to peeling forces.

Inventive Principle:

Principle #40Composite materials

2Reliability

If discontinuous long fibers are used in the connection interface, then the fiber density increases and resin-rich areas are eliminated, but the manufacturing process becomes more complex requiring pre-compaction and pre-curing steps

Engineering Contradiction:

Improvefiber density at connection interfaceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the composite part into two distinct portions: the main body made of continuous fibers and the connection interface portion made of discontinuous long fibers. This segmentation allows each portion to be manufactured with optimized fiber types and processes, with the connection interface portion requiring pre-compaction and pre-curing to achieve proper fiber density and resin distribution.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs preliminary action by implementing pre-compaction and pre-curing steps for the discontinuous long fiber portion before final assembly. The pre-compaction step consolidates the discontinuous fibers to the desired density, and the pre-curing step begins resin polymerization, ensuring the connection interface is properly prepared before being joined to the main body.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the connection interface is made homogeneous with continuous fiber contact, then peeling resistance improves, but the ability to adapt to complex geometries and repeated multi-directional loads is reduced

Engineering Contradiction:

Improveresistance to peeling forcesVSAvoidadaptability to complex geometries and repeated loads

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

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 composite parts with increased mechanical resistance, capable of withstanding repeated loads applied in different directions without risk of connection rupture, and allows for complex geometries that adapt to continuous fiber subassemblies, improving force transfer and resistance to peeling forces.

Implementation Method 1

polymerization of the first and second preforms so as to form a part made of composite material

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 2

pre-curing the first preform until an intermediate conversion stage of the first thermosetting resin corresponding to a solidification of said first resin

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS11072432B2Method for manufacturing a part made of a composite material comprising at least one portion forming a force-insertion portion or local thickened portion

Publication Date: 2021.07.27 SAFRAN SA

AI summary

A method for manufacturing of a part made of composite material including pre-compacting to a predetermined shape of a mixture of a first thermosetting resin with discontinuous long fibers so as to form a first preform, pre-curing the first preform until an intermediate conversion stage corresponding to a solidification of said first resin, contacting the first preform with a second preform including a fiber structure of continuous fibers impregnated with a second thermosetting resin, polymerizing the first and second preforms so as to form a part made of composite material including a body made of composite material including reinforcement made of continuous fibers consolidated by an organic matrix provided with a portion made of composite material including reinforcement made of discontinuous long fibers consolidated by an organic matrix.