Composite Carbon Fiber Mold Structure for Low-Pressure RTM
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Solution Overview
Problem
Current RTM processes face challenges with heavy, expensive, and bulky metal molds that require complex designs and high pressures, leading to low-quality products due to incomplete resin impregnation and rough finishes, while RTM-Light processes result in lower quality and slower production rates.
Innovation Solution
The use of molds made from pre-impregnated carbon fiber layers with resin, stiffened by ribs or reinforcing members, and cured in an oven or autoclave, allowing for lower injection pressures and precise mechanical fastening with gaskets and bushings to ensure complete impregnation and uniform resin distribution, while being lightweight and easy to handle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal molds are used in RTM process, then the molds can withstand high injection pressures, but the molds become heavy, expensive and bulky
Solution Approach 1:
The patent applies composite materials (specifically carbon fiber reinforced polymers) to manufacture molds that combine high strength with low weight. The composite mold structure provides sufficient mechanical strength to withstand RTM injection pressures while being significantly lighter than traditional metal molds, directly resolving the contradiction between pressure resistance and weight.
2Strength
If metal molds are used in RTM process, then the molds can withstand high injection pressures, but the design becomes complex due to thermal expansion considerations
Solution Approach 1:
Composite materials have different thermal expansion characteristics compared to metal, which simplifies the design process. The patent leverages this property to create molds with less complex designs, as composites exhibit more predictable and manageable thermal behavior during the curing cycle, reducing the need for complex compensation mechanisms.
3Weight of moving object
If RTM-Light process is used with semirigid molds, then the equipment becomes light and economic, but the injection pressure is low resulting in rough finishes and incomplete impregnation
Solution Approach 1:
The patent uses composite material molds that maintain structural rigidity and dimensional stability even at lower injection pressures. This allows the mold to preserve its shape and surface integrity during the RTM-Light process, enabling production of high-quality parts with smooth finishes and complete fiber impregnation while keeping equipment lightweight and economical.
4Weight of moving object
If known composite molds are used, then the molds are lighter, but they require complex supporting structures and are relatively thick, thus expensive
Solution Approach 1:
The patent applies local quality by strategically placing ribs and reinforcing members only in specific areas of the mold where structural support is needed, rather than making the entire mold thick. This localized reinforcement approach maintains mold strength and rigidity while minimizing overall material usage, keeping the mold lightweight and cost-effective.
Solution Approach 2:
The mold design segments the reinforcing structures into discrete ribs and members distributed throughout the mold body. This segmentation allows for optimized material placement, reducing the need for continuous thick sections while maintaining structural integrity, thereby lowering cost and 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 approach enables the production of high-quality products with increased productivity and reduced costs, as molds are lightweight, easy to automate, and handle, with improved thermal expansion compensation and reduced defects.
Implementation Method 1
the cure of the final products with the heating of these molds in an oven or an autoclave
Data Source
AI summary
A mold for manufacturing products made of composite materials, which comprises at least one functional portion made of a composite material joined to at least one interface made of a composite material which projects at least partially around the functional portion, said mold being provided with one or more mechanic fastening devices for the coupling with at least another mold.