Composite Internal Passageway Groove Layup Method
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Solution Overview
Problem
Conventional methods for creating composite articles with internal passageways are challenging due to the difficulty, time, and expense of manufacturing, especially when using fiber-reinforced polymeric materials, which are often heavier and more costly than metallic counterparts.
Innovation Solution
A method involving a layup tool process where a base layup with a groove is created, a mandrel or tube is placed within the groove, and a top layup is applied, followed by curing, allowing for the efficient formation of internal passageways in fiber-reinforced polymeric composite articles, using tools that are easier to manufacture and modify compared to traditional casting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials and casting processes are used to make articles with internal passageways, then the articles have required mechanical strength, but the articles become heavy and the patterns are expensive with long lead times
Solution Approach 1:
The patent applies composite materials by using fiber-reinforced polymers (such as carbon fiber, glass fiber, or aramid fiber reinforced with epoxy, polyester, or vinyl ester resins) to replace traditional metallic materials. This allows the article to maintain required mechanical strength while significantly reducing weight, as composite materials offer high strength-to-weight ratios compared to metals
2Shape
If conventional casting processes are used to make composite articles with internal passageways, then internal passageways can be formed, but the manufacturing process becomes very difficult, time consuming, and expensive
Solution Approach 1:
The patent applies preliminary action by pre-forming grooves in the mold before the composite layup process. These grooves are created using conventional machining or additive manufacturing techniques before the composite material is applied. This preliminary preparation simplifies the subsequent composite manufacturing process, allowing internal passageways to be formed more easily and with less complexity than conventional casting methods
Solution Approach 2:
The patent applies segmentation by dividing the mold into multiple sections or layers that can be separately prepared and assembled. The grooves for internal passageways are formed in specific sections of the mold, allowing independent preparation and reducing overall manufacturing complexity. This modular approach enables easier fabrication and assembly compared to monolithic casting patterns
3Ease of manufacture
If conventional casting patterns are used, then molds can be made to form castings, but the patterns are expensive, require long lead times, and are difficult to manufacture
Solution Approach 1:
The patent applies parameter changes by utilizing modern manufacturing techniques such as additive manufacturing (3D printing) or CNC machining to create mold grooves, replacing traditional expensive and time-consuming pattern making processes. These advanced manufacturing methods reduce material waste, shorten production cycles, and lower costs while maintaining or improving mold precision and complexity
4Weight of moving object
If fiber-reinforced polymeric composite materials are used, then lighter weight articles can be produced, but making articles with internal passageways becomes very difficult, time consuming, and expensive
Solution Approach 1:
The patent applies preliminary action by pre-forming grooves in the mold before applying the fiber-reinforced composite material. This preliminary preparation ensures that the complex internal passageway geometry is established before the composite layup, making the manufacturing process more manageable and less complex than attempting to form passageways during or after composite curing
Solution Approach 2:
The patent uses the groove structure as an intermediary element that facilitates the formation of internal passageways in composite articles. The grooves act as molds within the mold, guiding the composite material to form the desired passageway geometry, thereby simplifying the overall manufacturing process and reducing complexity
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 enables the production of lighter-weight composite articles with internal passageways, reducing manufacturing costs and lead times, and facilitating easier tooling changes, thus overcoming the limitations of traditional metallic and polymeric composite manufacturing.
Implementation Method 1
curing the base layup and the top layup
Data Source
AI summary
In one particular embodiment, a method for making a fiber-reinforced, composite article having an internal passageway includes providing a layup tool, fiber placing a base layup onto the layup tool, and generating a groove in the base layup. The method further includes placing a mandrel in the groove, fiber placing a top layup onto the base layup and the mandrel, curing the base layup and the top layup, and removing the mandrel from the base layup and the top layup. In another particular embodiment, the mandrel is replaced with a non-removable tube.