Composite Rim Manufacturing Using Self-Inflating Air Bag
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Solution Overview
Problem
Conventional composite rim manufacturing methods require manual placement of air blowing ports on air bags, leading to inconsistent air pressure and reduced structural strength due to reliance on operator skill, and are prone to air leakage, affecting yield and product quality.
Innovation Solution
A method involving a completely closed annular air bag with a thermal expansion material inside, which expands to inflate and solidify the composite rim within a mold, eliminating the need for external openings and ensuring consistent pressure for improved bonding density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual placement of air blowing ports on air bags is used, then the air bag can be inflated to apply pressure for solidifying the composite rim, but the manufacturing precision and consistency of air pressure are reduced due to reliance on operator skill
Solution Approach 1:
The air bag is designed as a self-contained component with an integrated inflating valve that automatically provides the necessary air pressure when activated, eliminating the need for manual port placement and ensuring consistent pressure application throughout the solidification process
Solution Approach 2:
The inflating valve enables controlled change in the air pressure parameter within the air bag, allowing precise regulation of the pressure applied to the composite rim during solidification, thereby improving manufacturing precision
2Object-generated harmful factors
If additional components like nozzles or inflating valves are added to the air bag, then the air bag can be inflated to apply pressure, but the device complexity increases and the air bag is no longer completely closed
Solution Approach 1:
The harmful through-opening is extracted from the air bag design by using a sealed air bag that inflates from the inside, eliminating air leakage paths while maintaining the necessary inflation function through an integrated valve mechanism
Solution Approach 2:
The air bag serves multiple functions: it acts as a pressure application device, a sealing component, and contains the thermal expansion material, eliminating the need for separate nozzles or valves and reducing overall device complexity
3Strength
If air pressure is increased to improve bonding density, then the layers of pre-preg composite are pressed together more effectively, but the resin content of the final product decreases which also reduces strength
Solution Approach 1:
The air pressure is applied periodically during the solidification process, allowing the resin to flow and bond layers together effectively while maintaining controlled pressure that prevents excessive resin removal, thereby balancing bonding density with resin content
Solution Approach 2:
The thermal expansion material undergoes controlled phase change from solid to gas, providing periodic pressure application that optimizes both bonding density and resin content by applying pressure in controlled intervals rather than continuously
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 enhances precision, yield, and structural strength of the composite rim by ensuring consistent air pressure and eliminating manual errors in air bag port placement, resulting in higher quality products with reduced scrap rates.
Implementation Method 1
heating the thermal expansion material so that the thermal expansion material expands and inflates the air bag
Data Source
AI summary
A method of manufacturing a composite rim includes following steps of: disposing a composite material on an outer surface of an air bag to form a semi-formed rim, wherein the air bag is a completely closed annular tube without any through opening on the outer surface and contains a thermal expansion material thereinside; disposing the semi-formed rim in a mold; and heating the thermal expansion material so that the thermal expansion material expands and inflates the air bag and the semi-formed rim is then solidified.