Composite Part Production Using Granular Filtration Layers
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Solution Overview
Problem
Existing methods for manufacturing composite material parts, such as those used in turbomachines, face limitations in adaptability for complex geometries and high implementation costs due to the use of rigid porous materials, which are difficult to remove and costly to implement.
Innovation Solution
A method involving a mold with a fibrous texture, a granular filtration layer, and a retention element is used to introduce a suspension, where the liquid medium is drained through a permeable evacuation surface, allowing matrix particles to be retained in the fibrous texture, and a surface layer is formed from filtration particles, eliminating the need for removing porous parts and enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid porous material part is used for liquid medium evacuation, then the liquid medium can be effectively drained, but the adaptability for complex geometries is limited and implementation cost increases
Solution Approach 1:
The invention extracts the porous material from the mold after infiltration, eliminating the need for complex rigid porous structures during the process. The porous material serves only its evacuation function temporarily, then is removed, allowing complex geometries to be achieved without the constraints of rigid porous support structures.
Solution Approach 2:
The invention utilizes porous material properties during the infiltration process to enable liquid medium evacuation, but avoids the limitations of permanent rigid porous structures. The porous material is used temporarily during manufacturing and then removed, combining the benefits of porous evacuation with the flexibility needed for complex geometries.
2Reliability
If a rigid porous material part is used for liquid medium evacuation, then the liquid medium can be effectively drained, but implementation cost increases
Solution Approach 1:
The porous material is extracted from the final product, meaning it doesn't need to be permanently integrated into the mold structure. This allows for simpler, less expensive mold designs while maintaining effective evacuation during the process. The porous material can be a separate, removable component rather than an integrated expensive fixture.
Solution Approach 2:
The porous material functions as a temporary, disposable element during the infiltration process. It serves its evacuation purpose and is then removed, eliminating the need for expensive, durable porous structures that would need to be permanently installed in the mold system.
3Reliability
If porous material is used during infiltration, then liquid medium evacuation is enabled, but the porous part must be removed after demolding
Solution Approach 1:
The porous material is extracted from the mold after infiltration, simplifying the overall process. By removing the porous material at the appropriate stage, the invention avoids the complexity of integrating permanent porous structures into the final product while maintaining effective evacuation during manufacturing.
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 method improves the mechanical properties of the surface layer and reduces implementation costs by integrating a granular filtration layer into the composite material part, enabling better adaptability for complex geometries and reducing the need for costly removal steps.
Implementation Method 1
the liquid medium passing through the drainage surface, the granular filtration layer and the retention element to be evacuated through the permeable evacuation surface, and the matrix particles being retained in the porosity of the fibrous texture by the granular filtration layer
Implementation Method 2
a retention element for the granular layer distinct from the latter and located between the permeable evacuation surface and the drainage surface
Data Source
Figure 1~2
Figure 3~4
Figure 5~6B
AI summary
The invention relates to a method for producing a part made of composite material, said method comprising at least: - obtaining a mould comprising (i) a fibrous structure (6), (ii) a granular filtration layer (5a) located between a drainage surface (SD) of the structure and a permeable discharge surface (4) and comprising a powder of filtration particles (50a), and (iii) an element (5b) for retaining the granular layer, which element is separate from said layer and located between the permeable discharge surface and the drainage surface, - introducing a suspension (1) comprising matrix particles (PM) in a liquid medium (ML) through an introduction surface (SI) of the fibrous structure that is separate from the drainage surface, the liquid medium passing through the drainage surface, the granular filtration layer and the retention element to be discharged through the permeable discharge surface, and the matrix particles being retained in the pores of the fibrous structure by the granular filtration layer, and - forming the part made of composite material by forming a matrix in the pores of the fibrous structure using the matrix particles, and forming a surface layer of this part using the filtration particles.