Composite Curing Pressure Gradient Gas Evacuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for manufacturing composite parts with polymer matrices face challenges in effectively evacuating air bubbles, leading to heterogeneity and reduced mechanical properties, and are complex and labor-intensive due to the arrangement of vents.
Innovation Solution
A process and device that apply a pressure gradient during the curing of composite blanks, where higher pressure is applied to one zone and lower pressure to another, causing gas bubbles to migrate out, using a pressurization member that can be an inflatable bladder with varying thickness or modulus of elasticity to facilitate this gradient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vacuum bag with multiple vents is used to evacuate gas from the composite part, then gas evacuation is attempted, but the arrangement becomes complex and labor-intensive
Solution Approach 1:
The patent extracts the gas evacuation function from the complex multi-vent system and concentrates it into a single dedicated evacuation zone. This simplifies the device by removing unnecessary vents while maintaining effective gas removal through the pressure gradient mechanism.
Solution Approach 2:
The single evacuation zone serves multiple purposes: it is the sole exit for gas bubbles, the endpoint for the pressure gradient, and the location where resin flow converges. This multi-functionality eliminates the need for separate vents while maintaining comprehensive gas evacuation capability.
2Reliability
If multiple vents are arranged in different zones of the composite part, then gas evacuation coverage is increased, but the manufacturing process becomes more onerous and shaping becomes more difficult
Solution Approach 1:
The patent merges multiple evacuation functions into a single evacuation zone. Instead of distributing vents across different zones, all gas evacuation activity is consolidated into one location, simplifying the manufacturing process while maintaining complete gas removal through the directed pressure gradient.
Solution Approach 2:
The evacuation zone is strategically positioned to receive gas bubbles from all regions of the composite part through the pressure gradient. This localized high-quality evacuation point replaces the need for multiple distributed vents, making the process easier to operate.
3Ease of manufacture
If uniform pressure is applied during curing, then the composite part is simplified to manufacture, but gas bubbles remain trapped creating heterogeneity
Solution Approach 1:
The patent changes the pressure parameter from uniform to graduated (pressure gradient). By varying the pressure parameter across different zones, the system maintains manufacturing simplicity while achieving complete gas bubble elimination through the directed flow toward the evacuation zone.
Solution Approach 2:
The pressure gradient, which adds apparent complexity to the pressure application, actually converts the harmful trapped gas bubbles into beneficial directed flow toward the evacuation zone. The pressure difference that could be seen as complicating the process becomes the mechanism for ensuring complete gas removal.
4Reliability
If pressure is applied during curing to evacuate gas, then gas content is reduced, but the process becomes more complex compared to known processes
Solution Approach 1:
The pressure application is localized to specific zones rather than requiring complex multi-point control. The graduated pressure is applied with a single device that creates different pressure levels in different zones, simplifying the overall system while achieving effective gas evacuation.
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 effectively reduces gas content within the composite part, improving mechanical properties and simplifying the manufacturing process by ensuring efficient gas evacuation without additional costs or complexity.
Implementation Method 1
pressure is exerted in the form of a pressure gradient, said pressure being applied to said pressed face of said composite blank between at least one first zone, named zone of maximum pressurisation, of said pressed face and at least one second zone, named gas evacuation zone
Data Source
AI summary
Disclosed is a process for manufacturing a part, named composite part, formed from at least one composite material including at least one layer of a reinforcing structure impregnated with a polymer matrix within which the reinforcing structure extends, wherein: a composite blank of the composite part is prepared; and a step of curing the polymer matrix of the composite blank is carried out, exerting a pressure on at least one pressed face of the composite blank. The pressure is exerted in the form of a pressure gradient applied to the pressed face of the composite blank so as to cause the gas present within the composite part to flow from a zone of maximum pressurization to a gas evacuation zone. Also disclosed is a device for manufacturing such a part.