Composite Resin Infusion Tool With Adjustable Cure Pressure Control
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Solution Overview
Problem
Conventional systems for forming composite structures are time- and labor-intensive, requiring precise machined tooling and hard stops, making it difficult and expensive to produce high-quality composite structures at high rates.
Innovation Solution
A system and method using a tool with an adjustable stop to maintain constant pressure during resin infusion and cure, controlling tool position to accommodate resin shrinkage and ensure consistent pressure across the composite part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional systems use precisely machined tooling and hard stops to control cure pressure and part thickness, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies the Dynamics principle by replacing static hard stops with a dynamic feedback control system. The system continuously monitors cure pressure and automatically adjusts the tool lid position to maintain constant pressure, adapting to resin shrinkage and volume changes during curing. This dynamic approach achieves precise pressure control without requiring complex precisely-machined tooling or fixed hard stops.
2Manufacturing precision
If conventional systems use precisely machined tooling and hard stops to control cure pressure and part thickness, then manufacturing precision is improved, but productivity decreases due to time- and labor-intensive processes
Solution Approach 1:
The patent applies the Self-service principle by implementing an automated feedback control system that self-adjusts during the curing process. The system monitors pressure and automatically positions the tool lid to maintain constant pressure, eliminating the need for manual intervention and complex tooling setup. This automation reduces labor intensity and time requirements while maintaining precise part thickness control.
3Ease of operation
If conventional systems use hard stops to control tool position, then ease of operation is improved, but manufacturing precision deteriorates due to inability to accommodate resin shrinkage
Solution Approach 1:
The patent applies the Feedback principle by implementing a closed-loop control system that continuously monitors cure pressure and uses this information to automatically adjust the tool lid position. This feedback mechanism ensures constant pressure maintenance throughout the curing process, accommodating resin shrinkage and volume changes while keeping the operation simple through automation.
4Manufacturing precision
If conventional systems use precisely machined tooling, then manufacturing precision is improved, but cost increases
Solution Approach 1:
The patent applies the Mechanics substitution principle by replacing complex mechanical precision tooling with an automated feedback control system. Instead of relying on precisely-machined hard stops and mechanical constraints, the system uses sensors and automated positioning to maintain constant pressure. This substitution reduces tooling manufacturing costs while achieving the same or better pressure control precision.
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 high-quality composite structures to be produced efficiently by maintaining constant pressure throughout the cure process, preventing defects and ensuring consistent quality.
Implementation Method 1
As the resin shrinks during cure, the position of the tool lid is adjusted using the adjustable stop to maintain a constant pressure
Data Source
AI summary
A system for forming a composite structure includes a tool for infusing a dry preform with a resin. The tool includes a tool base and a tool lid. The tool base includes a base surface. The tool lid includes a lid surface. The system includes an adjustable stop that is positioned between the tool base and the tool lid. The base surface and the lid surface form a portion of a tool cavity. The tool lid is movable relative to the tool base to generate an internal pressure within the tool cavity. The adjustable stop controls a tool position of the tool lid relative to the tool base to achieve a predetermined value for the internal pressure.