Composite Spacer Pre-Compression for Shape Definition
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Solution Overview
Problem
The manufacturing of structural composite parts with specific shapes, such as contours or reliefs, is challenging due to excessive pressure causing random crushing of spacers, especially when the spacer thickness exceeds 15 mm, and existing methods are costly or inefficient.
Innovation Solution
A method involving pre-compression of the spacer in a non-heating mold with relief imprints and subsequent stacking in a heating mold with corresponding imprints to maintain a constant air gap, using a water-based adhesive and thermosetting resin for bonding, and evacuating water vapor during polymerization to achieve precise shaping without excessive pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure is applied during compression in a heated mold to achieve specific shapes, then the shape definition improves, but the spacer collapses and structural integrity deteriorates
Solution Approach 1:
The spacer is pre-compressed in an unheated mold before being placed in the heated mold, creating preliminary impressions that define the shape. This preliminary action allows the spacer to be pre-formed without the thermal effects that would cause collapse during final curing, thus achieving both shape definition and structural integrity
Solution Approach 2:
The manufacturing process is divided into two distinct stages: first compression in an unheated mold to create shape impressions, then heating and final compression in a heated mold. This segmentation allows each stage to perform its specific function optimally without interfering with the other, resolving the contradiction between shape definition and structural integrity
2Manufacturing precision
If expanding polyurethane resin is used to fill cavities and define shapes, then shape definition improves, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive expanding polyurethane resin with a water-based adhesive that is much cheaper. The adhesive serves the same function of filling cavities and defining shapes during compression, achieving cost-effective manufacturing without sacrificing shape definition capability
Solution Approach 2:
The invention changes the material parameter from expanding polyurethane resin to water-based adhesive. This parameter change maintains the functional capability of filling cavities and defining shapes while dramatically reducing material cost, thus resolving the contradiction between shape definition and manufacturing cost
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 allows for the production of structural composite parts with well-defined shapes and reduced costs, as it avoids high-pressure requirements and uses cost-effective materials, enabling the use of spacers with varying thicknesses and maintaining the structural integrity of the composite parts.
Implementation Method 1
the heating being carried out at a temperature and for a duration allowing polymerization or crosslinking of the thermosetting resin
Implementation Method 2
a first heated mold includes means for evacuating water vapor formed during the compression and heating step
Data Source
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AI summary
A method for manufacturing a composite component (10) is disclosed, said method comprising the following steps: - stacking, in a first heated mould, a first mat, a spacer and a second mat, the mats being impregnated with thermosetting resin; and:• - compressing and heating the stack in order to polymerize the thermosetting resin. Said method comprises, prior to the stacking step, a step of compressing the spacer (114) in a non-heated second mould (30), an internal surface (34) of said second mould comprising an imprint (36) so as to shape the spacer to said imprint. An internal surface of the first mould comprises an imprint corresponding to the imprint (36) of the second mould. Thus, during the step of compression and of heating by the first mould, a gap between the spacer and said first mould is substantially constant. There is therefore no risk of the spacer being compressed randomly during the compression and heating step.