Composite Product Resin Transfer Injection for High-Rate Infusion
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Solution Overview
Problem
The aerospace industry faces challenges in achieving high production rates for composite aircraft components, particularly in manufacturing technologies that can meet the demand for lightweight components with efficient build rates, such as 8000/year, which is essential for Urban Air Mobility (UAM) applications.
Innovation Solution
A resin transfer injection method and apparatus are employed, utilizing preheated resin infusion under partial vacuum and controlled pressure within a tooling system to form composite products, ensuring precise cavity formation and resin distribution, followed by curing to achieve the desired fiber volume fraction and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional composite manufacturing methods are used, then manufacturing precision and structural integrity are maintained, but productivity is insufficient to achieve high build rates of 8000/year
Solution Approach 1:
The manufacturing process is segmented into two independent simultaneous infusions (first and second cavities) rather than sequential operations. This parallel processing approach doubles the effective production capacity without compromising the quality or integrity of each individual composite component.
Solution Approach 2:
The preform assembly is pre-fashioned to define the exact shape of the product before resin infusion. This preliminary preparation of the fiber architecture ensures that when resin is injected simultaneously into both cavities, the structural integrity and precision are maintained while enabling rapid production.
2Productivity
If resin is injected under high pressure to accelerate infusion, then productivity increases, but manufacturing precision and fiber volume fraction control deteriorate
Solution Approach 1:
The system dynamically changes pressure parameters during the infusion process. High pressure is applied initially to accelerate resin infusion and improve productivity, then pressure is reduced or balanced to maintain precise fiber volume fraction control. This parameter modulation resolves the contradiction between speed and precision.
Solution Approach 2:
The manufacturing system incorporates feedback mechanisms to monitor resin infusion progress and fiber volume fraction in real-time. Based on this feedback, injection pressure is automatically adjusted to maintain optimal fiber volume fraction while maximizing infusion rate, thereby achieving both high productivity and manufacturing precision.
3Loss of time
If tools are heated to high temperature to cure resin quickly, then processing time is reduced, but energy consumption increases
Solution Approach 1:
The tools are continuously heated throughout the resin infusion and curing process rather than using intermittent or post-processing heating. This continuous thermal action maintains optimal curing temperature throughout the entire cycle, reducing total curing time and energy consumption compared to methods requiring higher peak temperatures or extended heating periods.
Solution Approach 2:
The system exploits the phase transition of resin from liquid to solid during curing. By maintaining tools at a specific temperature range that optimizes this phase transition, the resin cures efficiently at moderate temperatures rather than requiring excessive heat, thereby reducing energy consumption while maintaining fast curing rates.
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 and apparatus enable rapid and efficient manufacturing of composite products with high fiber volume fractions, reducing processing times and assembly burdens, while maintaining structural integrity, suitable for aerospace components like wings and control surfaces.
Implementation Method 1
establishing a partial vacuum between the first and second tools
Implementation Method 2
using injection pressure of the resin and the partial vacuum to move the resin throughout the first and second cavities
Implementation Method 3
injecting a volume of pressurised preheated resin simultaneously into the first and second cavities
Implementation Method 4
allowing the first and second tools and the preform assembly to reach at least a predefined temperature
Implementation Method 5
The predefined temperature may be an injection temperature of the resin, for example in a range of 120° C. to 180° C. In a preferred embodiment, the predefined temperature is a resin cure temperature, for example a 180° C. resin cure temperature
Implementation Method 6
allowing the resin infused into the product preform to cure to form the composite product
Implementation Method 7
using at least one spacing device to form a first cavity between the preform assembly and the first tool and a second cavity between the preform assembly and the second tool
Data Source
AI summary
A resin transfer injection apparatus (1) for manufacturing a composite product is provided comprising first and second tools (7, 9), fashioned to at least partially correspond with first and second outer edges of the product, a preform assembly (11), comprising a product preform (12) fashioned to define a shape of the product, fitted between the first and second tools, at least one heater which allows the first and second tools (7, 9) and the preform assembly (11) to reach at least a predefined temperature, at least one spacing device to form a first cavity (19) between the preform assembly (11) and the first tool (7) and a second cavity (21) between the preform assembly (11) and the second tool (9), a tool movement mechanism for closing and opening the first and second tools (7, 9), at least one vacuum pump which establishes a partial vacuum between the first and second tools (7, 9), and a resin injection system which injects a volume of pressurised preheated resin simultaneously into the first and second cavities (19, 21), wherein injection pressure of the resin and the partial vacuum moves the resin throughout the first and second cavities (19, 21) and starts infusion of the resin into the product preform (12) of the preform assembly (11) simultaneously from the first and second cavities, the first and second tools (7, 9) are closed to reduce the first and second cavities (19, 21) and apply pressure to accelerate infusion of the resin into the product preform (12) of the preform assembly (11) simultaneously from the first and second cavities (19, 21) and the resin is allowed to cure to form the product.A method of using the apparatus for manufacturing a composite product is further provided.