Composite Part Liquid Compaction with Matched Fluid Density
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Solution Overview
Problem
Existing methods for manufacturing large but thin composite parts with ceramic or organic matrix, such as aeronautical rear body parts, face challenges in controlling dimensional tolerances and compaction pressure, leading to undesired variations in fiber volume ratios and thickness due to pressure differences between impregnation and compaction fluids.
Innovation Solution
A method using a flexible membrane to separate impregnation and compaction chambers, with a compression fluid having a density between 60% and 125% of the impregnation fluid's density, ensuring a constant compaction rate and precise pressure control by maintaining a low differential pressure, facilitated by a quasi-incompressible liquid and a series network for fluid management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flexible membrane is used instead of a counter-mold to manufacture large but thin parts, then the problems of tool tolerancing are overcome, but the compaction pressure applied to the preform is not identical over the entire height of the membrane, leading to undesired variations in fiber volume ratio and thickness
Solution Approach 1:
The invention changes the physical parameter of the compression fluid by selecting a liquid with specific density characteristics (between 60% and 125% of the impregnation fluid density). This parameter change ensures that the compaction pressure remains substantially constant over the entire height of the membrane, eliminating the pressure variations that cause non-uniform fiber volume ratios and thickness variations in the manufactured parts.
2Force
If compression fluid is injected into the compaction chamber to apply pressure to the membrane, then compaction pressure is applied to the preform, but the pressure difference between impregnation fluid and compression fluid is too high and difficult to control
Solution Approach 1:
The invention changes the density parameter of the compression fluid to be between 60% and 125% of the impregnation fluid density. This parameter adjustment ensures that the compaction pressure applied to the preform is substantial enough for effective impregnation while remaining easy to control, eliminating the difficulty in pressure control that occurs when using compression fluids with significantly different densities.
3Length of stationary object
If the part extends over a significant height in the impregnation chamber, then large but thin parts can be manufactured, but undesired variations in thickness appear due to pressure differences in the impregnation chamber
Solution Approach 1:
The invention changes the density parameter of the compression fluid to match closely with the impregnation fluid density (within 60%-125% range). This parameter change ensures that hydrostatic pressure differences due to height variations are minimized, allowing large but thin parts to be manufactured with uniform thickness throughout their entire height.
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
Achieves consistent compaction pressure across the part's height, maintaining precise fiber volume ratios and thickness, overcoming the limitations of previous methods by ensuring controlled pressure differentials and improved dimensional accuracy.
Implementation Method 1
injection of a compression fluid into the compaction chamber... pressure is first applied to the membrane by injecting a compression fluid into the compaction chamber
Implementation Method 2
the compaction pressure applied to the preform by the membrane, resulting from the pressure difference between the compression fluid and the impregnation fluid
Implementation Method 3
injection of an impregnation fluid comprising a matrix precursor into the impregnation chamber... pressure is exerted on the flexible membrane in order to make the slip penetrate through the fibrous preform
Implementation Method 4
solidification treatment of the matrix precursor within the fibrous preform so as to obtain a part made of composite material comprising a fibrous reinforcement bound by a solid matrix
Data Source
AI summary
A method for manufacturing a part made of composite material, includes the arrangement of a fibrous preform in the impregnation chamber of a mold, the impregnation chamber being closed by a flexible membrane separating the impregnation chamber from a compaction chamber, an impregnation fluid being injected into the impregnation chamber and a compression fluid being injected into the compaction chamber, the compression fluid being a liquid in which the value of the density is between 60% and 125% of the density of the impregnation fluid.