Composite Lattice Molding Using Heated Internal Fluid Pressure
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Solution Overview
Problem
Existing composite manufacturing methods face challenges such as interlaminar failure, porosity, and poor surface finish, especially in additively manufactured structures, leading to weak consolidation and vulnerability to crack propagation.
Innovation Solution
A method involving a floodable hollow lattice structure within a mold, where a fluid medium is injected and heated to increase pressure, consolidating both the shell and lattice structures of a composite component, while improving surface roughness through hydrostatic pressure and temperature expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If layer-by-layer additive manufacturing is used to manufacture composite structures, then manufacturing flexibility and complexity handling are improved, but consolidation between layers is weak and the structure becomes vulnerable to crack propagation
Solution Approach 1:
A preliminary composite component with hollow lattice structure is manufactured additively first, then subjected to fluid injection and heating treatment to achieve consolidation. The preliminary structure is prepared in advance with built-in consolidation capability through the hollow lattice design that will be filled with fluid medium.
Solution Approach 2:
A fluid medium is injected into the hollow lattice structure and heated to a processing temperature, causing the fluid to expand and generate pressure. This phase change and expansion of the fluid medium consolidates the composite layers by pressing them together within the shaping cavity.
2Reliability
If traditional pressure molding is used to consolidate composite layers, then layer consolidation is improved, but energy consumption increases
Solution Approach 1:
A fluid medium (liquid or gas) is injected into the hollow lattice structure to generate pressure for consolidation. The fluid pressure, enhanced by thermal expansion, consolidates the composite layers without requiring high-energy mechanical pressing systems.
Solution Approach 2:
The temperature of the fluid medium is increased to a processing temperature, causing thermal expansion that generates pressure for consolidation. By changing the temperature parameter of the fluid, sufficient consolidation pressure is achieved with lower energy input compared to traditional mechanical pressing.
3Manufacturing precision
If additively manufactured composite components are produced with tight tolerances, then dimensional precision is improved, but manufacturing complexity and difficulty increase
Solution Approach 1:
The preliminary composite component is additively manufactured with the hollow lattice structure first, establishing the basic geometry. Subsequent fluid injection and heating processes then refine the dimensional precision and surface quality without requiring extremely tight tolerances during the additive manufacturing step itself.
Solution Approach 2:
The fluid medium acts as an intermediary between the preliminary component and the final consolidated structure. It transmits pressure uniformly throughout the hollow lattice structure, enabling precise dimensional control and surface quality improvement without direct mechanical intervention.
4Ease of manufacture
If porosity is introduced during composite manufacturing, then manufacturing processability is improved, but interlaminar failure risk increases
Solution Approach 1:
The hollow lattice structure, which could be considered void space or porosity, is converted into a beneficial feature by filling it with fluid medium. The fluid-filled lattice structure then serves as a pressure generation system that consolidates the composite layers and eliminates harmful porosity, transforming the potential weakness into a strength.
Solution Approach 2:
The fluid medium undergoes thermal expansion when heated to processing temperature, generating pressure that consolidates the composite structure. This phase transition process eliminates porosity and strengthens interlaminar bonds, converting the previously harmful void spaces into a beneficial consolidation mechanism.
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 approach enables low-energy pressure molding, enhancing structural integrity and surface quality of composite components by consolidating layers and reducing energy consumption.
Implementation Method 1
Heating the fluid medium to the processing temperature facilitates the expansion of the fluid medium within the floodable hollow lattice structure
Implementation Method 2
heating the fluid medium may heat and reshape the preliminary composite structure
Implementation Method 3
Pressure is built up by the fluid molecules that expand under increased temperature and by means of the hydrostatic pressure within the floodable hollow lattice structure, the shell surface of the preliminary composite component presses towards the inner surface of the shaping cavity
Data Source
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AI summary
The present invention relates to a method of processing a composite component comprising one or more types of fibers and a thermoplastic. The method comprising: arranging a preliminary composite component (10) comprising a floodable hollow lattice structure (12) within a shaping cavity (116) of a mold (110); injecting a fluid medium into the floodable hollow lattice structure (12) of the preliminary composite component (10); and increasing the temperature of the fluid medium to a processing temperature, thereby: yielding the thermoplastic, and increasing a pressure within the shaping cavity (116) such that a shell surface (14) of the preliminary composite component (10) presses against a surface of the shaping cavity (116) while maintaining a lattice structure within the preliminary composite component (10) and such that both the shell and lattice structures of the preliminary composite component are consolidated. A system for processing the composite component is also presented.