Composite Mold Recess Filling for Fast Release Tool Preparation
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Solution Overview
Problem
Conventional methods for manufacturing composite structures require additional processing steps and the use of hazardous chemicals to prepare cure tools, leading to increased manufacturing time and inefficiencies.
Innovation Solution
The use of a releasable gap filler applied within mold recesses, which allows uncured composite material to be directly applied and cured without additional release layers, enabling easy removal of the cured composite material while leaving the gap filler in place, thus eliminating the need for additional processing steps and reducing mold preparation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional release layers and processing steps are used to prepare cure tools, then the composite material can be removed from the mold, but additional manufacturing time and hazardous chemicals are required
Solution Approach 1:
The patent extracts the release function from separate release layers and integrates it into the gap filler material itself. The gap filler is formulated with release properties, eliminating the need for additional release layers and reducing mold preparation steps while maintaining ease of composite removal.
Solution Approach 2:
The gap filler material performs multiple functions: it provides the release property to enable easy removal of cured composite, fills gaps in the mold recesses, and serves as a preparation layer. This multi-functionality eliminates the need for separate release layers and reduces manufacturing time.
2Ease of manufacture
If additional release layers are applied over gap filler, then release function is provided, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the release function with the gap filler material by formulating the gap filler with release properties. This combination eliminates the need for separate release layers, simplifying the manufacturing process while maintaining ease of composite removal.
Solution Approach 2:
The gap filler material is designed to perform multiple functions including providing release properties, filling gaps, and serving as a preparation layer. This multi-functionality reduces process complexity by eliminating additional release layers.
3Reliability
If conventional mold preparation methods are used, then the mold surface is prepared for curing, but hazardous chemicals and additional processing steps are required
Solution Approach 1:
The gap filler material is designed as a disposable, non-hazardous alternative to conventional chemical release agents. It provides reliable mold preparation and release functionality without requiring hazardous chemicals, eliminating harmful factors while maintaining preparation reliability.
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 reduces manufacturing time, eliminates the use of hazardous chemicals, and simplifies the manufacturing process by allowing for efficient removal of composite materials without damaging the mold, thereby improving production efficiency.
Implementation Method 1
After the releasable gap filler is cured
Implementation Method 2
The uncured composite material is cured to form a cured composite material on the mold
Data Source
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AI summary
Methods of forming a composite product are presented. A releasable gap filler (218, 402) is applied within a recess (206) of a mold (202). An uncured composite material (204) is applied directly over the releasable gap filler (218, 402) and onto the mold (202). The uncured composite material (204) is cured to form a cured composite material on the mold. The cured composite material is removed from the mold and the releasable gap filler.