Fiber Composite Sandwich with Shape Memory Alloy Wires
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Solution Overview
Problem
Existing methods for producing fiber-reinforced composites with shape memory capabilities are complex and lack simple control mechanisms for controlled shape changes.
Innovation Solution
A sandwich component comprising two cover layers and a core layer with wires made of molding metal is produced by compressing and heating a semi-finished product in a press, where the wires are arranged parallel and heatable, allowing for controlled shape changes through temperature-dependent lattice transformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional manufacturing methods (hand lay-up, spray-up, RTM, resin transfer molding) are used for composite structures, then design flexibility and structural integration are improved, but manufacturing precision and quality control deteriorate due to high skill requirements and variability
Solution Approach 1:
The manufacturing process is segmented into distinct stages: pre-preg placement in open mold, vacuum bagging, and autoclave curing. This segmentation allows each stage to be optimized independently, reducing skill requirements while maintaining precision.
Solution Approach 2:
Manual manipulation and skill-based processes are replaced with vacuum bagging systems and automated autoclave curing. The vacuum system provides consistent pressure distribution, eliminating variability associated with manual pressure application.
2Strength
If advanced composite materials and processes are adopted to improve performance, then structural strength and stiffness are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The process utilizes controlled parameter changes during autoclave curing (temperature, pressure, vacuum levels) to achieve optimal material properties. These controlled changes enable high-performance composites through a standardized process rather than complex manual techniques.
Solution Approach 2:
The invention employs pre-preg composite materials that combine resin and reinforcement in a controlled factory setting, ensuring consistent material properties. This approach achieves high structural performance while simplifying the manufacturing process compared to traditional layer-by-layer hand lamination.
3Ease of manufacture
If traditional manufacturing approaches are used for sandwich structures with metallic foam cores, then ease of manufacture is maintained, but manufacturing precision and core consistency deteriorate
Solution Approach 1:
The metallic foam core is pre-fabricated to precise dimensions and specifications before being placed in the mold. This preliminary action ensures core consistency is achieved through controlled manufacturing of the core itself, rather than attempting to control it during the composite lamination process.
Solution Approach 2:
The vacuum bagging system acts as an intermediary that uniformly distributes pressure across the entire sandwich structure during curing. This intermediary mechanism ensures consistent bonding between the pre-preg layers and the foam core, achieving manufacturing precision while maintaining ease of manufacture.
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
The method enables the production of adjustable, lightweight components with controlled shape changes, enhancing mechanical properties and simplifying the control of shape transformations.
Implementation Method 1
The autoclave process is used to manufacture the sandwich material and composite skin panels
Implementation Method 2
The autoclave process is used to manufacture the sandwich material and composite skin panels
Data Source
Figure 1
Figure 2
AI summary
Sandwich component comprising at least two cover layers and a core layer which contains wires made of molding metal.