Composite Fabrication With Nanostructure Embedding and Low Voids
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Solution Overview
Problem
Existing methods for fabricating composite materials often result in high void content due to the use of autoclaves, which are costly and complex, and do not effectively embed nanostructures within the polymer substrates, leading to suboptimal interlaminar shear strength.
Innovation Solution
A method involving the use of nanostructures between polymer substrates in a low-pressure environment, where the substrates are heated to embed the nanostructures within the polymer, reducing void formation by leveraging capillary forces for uniform polymer flow and channel filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If autoclave is used for fabricating composite materials, then interlaminar shear strength can be achieved, but device complexity and fabrication cost increase
Solution Approach 1:
The patent extracts and eliminates the autoclave from the fabrication process by replacing it with a low-pressure environment (less than 3 bar absolute pressure). This removes the complex high-pressure sealing and heating system while achieving the same embedding effect through capillary forces alone, thus reducing device complexity while maintaining strength.
Solution Approach 2:
The patent introduces capillary forces as an intermediary mechanism between the polymer substrate and nanostructures. This intermediary force replaces the need for autoclave pressure, enabling the polymer to flow and embed nanostructures through surface tension and capillary action in a low-pressure environment, thereby simplifying the fabrication system.
2Reliability
If autoclave is used for fabricating composite materials, then composite formation is achieved, but fabrication cost increases
Solution Approach 1:
The patent removes the expensive autoclave equipment from the fabrication process and replaces it with a simple low-pressure environment system. This extraction of the high-cost component maintains reliable composite formation through capillary forces while significantly reducing fabrication costs.
Solution Approach 2:
The patent employs inexpensive, easily replaceable components in the low-pressure environment system compared to the expensive autoclave. The simplified system uses standard laboratory equipment and consumables that are much cheaper, making the fabrication process more economically viable while maintaining product quality.
3Device complexity
If conventional methods are used without nanostructures, then fabrication is simpler, but void content increases
Solution Approach 1:
The patent applies local quality by incorporating nanostructures specifically at the interface between polymer substrates where voids typically form. These localized nanostructures serve as embedding points that guide polymer flow and eliminate voids in critical regions without requiring complex changes to the overall fabrication process.
Solution Approach 2:
The patent introduces capillary forces as an intermediary mechanism that mediates between the polymer substrate and nanostructures. This intermediary force enables the polymer to naturally flow into and embed the nanostructures, creating a dense void-free interface while maintaining fabrication simplicity through a low-pressure environment.
4Manufacturing precision
If high pressure is applied during heating, then polymer embedding is effective, but device complexity increases
Solution Approach 1:
The patent changes the pressure parameter from high pressure (autoclave conditions) to low pressure (less than 3 bar absolute). This parameter change is achieved by modifying the environment to leverage capillary forces, which are sufficient for effective embedding at low pressures, thereby eliminating complex pressure control systems while maintaining embedding effectiveness.
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 voids in composite materials, maintaining high interlaminar shear strength while eliminating the need for autoclaves, thus lowering fabrication costs and complexity.
Implementation Method 1
heating the first substrate and/or the second substrate such that polymer within the first substrate and/or polymer within the second substrate softens and/or melts
Implementation Method 2
leveraging capillary forces for uniform polymer flow and channel filling
Data Source
AI summary
Methods and systems for the fabrication of composite materials are generally described. Certain inventive methods and systems can be used to fabricate composite materials with few or no defects. According to certain embodiments, composite materials are fabricated without the use of an autoclave. In some embodiments, composite materials are fabricated in low pressure environments.