Laminated Composite Preformed Release Layer Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current production processes for laminated composite materials face challenges such as lengthy cycle times, labor-intensive processes, inclusion of air leading to pores, and high costs due to the need for extensive surface coating, making it difficult to produce high-quality, large series of parts efficiently.
Innovation Solution
A process involving a preformed additional layer of material, adapted through techniques like deep-drawing or injection molding, which is bonded to the composite material to improve surface quality, reduce cycle time, and eliminate the need for form release agents, allowing for efficient movement of non-cured parts and reduced wear on production molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a form release agent is used to prevent bonding to the mold cavity, then the product can be removed from the mold, but air inclusions occur due to reduced surface energy and insufficient wetting
Solution Approach 1:
The invention extracts the form release function from the mold cavity surface and relocates it to a separate form release layer. This layer is applied to the cavity surface but is not bonded to it, allowing easy removal of the cured product while preventing air inclusions. The form release layer acts as an intermediary that provides release functionality without interfering with resin wetting of the fiber reinforcement.
Solution Approach 2:
The form release layer serves as an intermediary between the mold cavity and the composite laminate. It mediates the interaction by providing a non-stick surface for easy removal while maintaining sufficient surface energy to allow complete wetting by the resin, thus preventing air trapping. This intermediary layer resolves the contradiction between ease of removal and product quality.
2Productivity
If the tool/press is used for both curing and fiber layout preparation, then equipment utilization is maintained, but production cycle time increases due to waiting and temperature adjustment delays
Solution Approach 1:
The invention segments the tooling system into two independent components: a curing tool for curing the laminate and a layout tool for preparing the fiber reinforcement. This segmentation allows both tools to operate independently and simultaneously, eliminating waiting time for equipment availability and temperature adjustments. Each tool can be optimized for its specific function and used continuously without interruption.
3Manufacturing precision
If extensive surface coating is applied to achieve high quality surface, then surface quality is improved, but production time and cost increase significantly
Solution Approach 1:
The invention performs the surface preparation action preliminarily by applying a form release layer to the mold cavity before laying the fibers. This layer creates a smooth, defect-free surface on the cured product that eliminates the need for subsequent extensive coating operations. The surface quality is built-in during the molding process rather than added afterward, significantly reducing production time and cost.
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 composite parts with improved durability, reduced cycle time, and elimination of pores, allowing for a finished surface that does not require additional varnishing, with enhanced bonding and protection against scratches and UV exposure.
Implementation Method 1
at least one separate additional layer of material which is adapted to a surface of the final product by preforming in a preforming tool, e.g. by deep-drawing
Implementation Method 2
injection molding in an injection molding tool
Implementation Method 3
bonded to the composite material to improve surface quality
Implementation Method 4
The form release agent causes a reduction of the surface energy and avoids sufficient wetting of the mould surface which leads to inclusion of air
Data Source
AI summary
The invention is directed to a process for the making of a product out of laminated composite material. The process in general comprises preforming at least one layer of material such that it corresponds to a surface of a part; applying layers of fibers to the preformed layer of material; and bonding the fibers by a resin to form a laminated composite material.