Composite Preform Segmentation for Complex Geometry and Strength
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Solution Overview
Problem
Current methods for producing fiber-reinforced composite materials with continuous fibers cannot achieve both high mechanical characteristics and complex geometries, as compression molding techniques are limited to simple shapes, while vacuum bagging, vacuum infusion, and resin transfer molding are necessary for complex geometries but lack mechanical superiority.
Innovation Solution
A method combining compression molding for forming sheets with subsequent shaping and assembly of pieces to create complex geometries, using vacuum bagging, vacuum infusion, or resin transfer molding for consolidation, applying fibrous substrates to reinforce and complete the geometry, and optionally treating in an autoclave for enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If compression molding technique is used, then mechanical characteristics are improved, but geometry complexity is limited
Solution Approach 1:
The method divides the complex-shaped preform into multiple simpler preforms that can be individually manufactured using compression molding, then assembles them into the final complex geometry. This segmentation allows each component to achieve high mechanical properties through compression molding while the assembled structure attains the required complex shape.
Solution Approach 2:
The patent describes inserting one preform into another preform to create the final complex geometry. This nesting approach allows multiple compression-molded components to be combined hierarchically, maintaining the mechanical advantages of compression molding for each component while achieving overall geometric complexity.
2Shape
If vacuum bagging or resin transfer molding is used, then geometry complexity is improved, but mechanical characteristics deteriorate
Solution Approach 1:
Instead of using vacuum bagging or resin transfer molding for the entire complex structure, the method segments the structure into multiple parts that can be manufactured using compression molding. This avoids the mechanical property deficiencies of vacuum-based methods while still achieving complex geometries through assembly.
Solution Approach 2:
The patent combines multiple compression-molded preforms into a single complex structure through assembly operations such as insertion and joining. This merging strategy allows the benefits of compression molding (superior mechanical properties) to be retained while achieving the geometric complexity that would otherwise require vacuum-based methods.
3Strength
If multiple techniques are combined, then both geometry complexity and mechanical characteristics are improved, but process complexity increases
Solution Approach 1:
The process segments the manufacturing into distinct stages: compression molding of individual preforms, then assembly of these preforms into the final complex structure. This segmentation allows each stage to use the most appropriate technique for that specific task, improving overall performance while keeping each individual step relatively simple and well-defined.
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
Enables the production of preforms with complex geometries that possess superior mechanical characteristics, combining the advantages of compression molding with the ability to form intricate shapes, suitable for applications like aerospace and automotive components.
Implementation Method 1
the compression molding technique allows a greater forming pressure to be exerted than with the other techniques. This gives an improved packing of the fibers and, in general, a composite with superior mechanical characteristics
Implementation Method 2
During any molding process, the polymer composition, impregnating the fibers, forms a binding matrix, which fixes the fibers to one another
Implementation Method 3
vacuum bagging, vacuum infusion, and resin transfer molding techniques
Data Source
Figure 1a
Figure 1b
Figure 2a~2f
AI summary
The invention relates to a method for making a preform in a fiber-reinforced composite material with continuous fibers, said preform having a predefined complex geometry. The method comprises the following steps: a) forming by compression molding technique one or more sheets in reinforced-fiber composite material; b) shaping from said one or more sheets in a fiber-reinforced composite material a plurality of pieces, the specific shape and size of each of said piece being chosen so that together such plurality of pieces can define, at least partially, the predefined complex geometry of said preform; c) assembling said pieces together to form a structure having a geometry corresponding, at least in part, to the predefined complex geometry of the preform to be made; d) consolidating said structure by means of vacuum bagging, vacuum infusion or resin transfer molding technique by applying fibrous substrates, in laminar form, to said structure at least in predefined portions thereof, to complete the geometry thereof, according to said predefined complex geometry and/or to reinforce said structure, thus obtaining a consolidated structure, which constitutes said preform with said predefined complex geometry.