Composite Tool Fabrication Using Low and High Temperature Resin Laminates
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Solution Overview
Problem
The traditional method of fabricating composite tools using high temperature cured resins like BMI and benzoxazine is costly and time-intensive due to multiple heating cycles, thick laminate layers, and the use of multiple substructures, which leads to heating variations and structural issues like warping and twisting.
Innovation Solution
The method involves forming a composite tool using a reduced number of heating cycles by creating a low temperature cured resin laminate over a master mold, which is then affixed to a substructure and overlaid with a high temperature cured resin laminate, both being cured at specific temperature ranges to achieve thinner, more uniform layers and fewer substructures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple heating cycles are used to cure intermediate mold and laminate layer, then complete curing is achieved, but fabrication time and cost increase
Solution Approach 1:
The patent combines the curing of the intermediate mold and laminate layer into a single heating cycle. The intermediate mold is configured to be cured at the same temperature range as the laminate layer, allowing both components to undergo curing simultaneously in one autoclave cycle rather than requiring separate heating cycles for each component.
2Ease of manufacture
If thick laminate layers are used to ensure uniform thickness, then manufacturing simplicity is maintained, but heating variations during curing occur
Solution Approach 1:
The patent divides the laminate structure into multiple thinner plies stacked together rather than using a single thick layer. This segmentation into thinner individual plies allows for more uniform heat penetration and curing throughout the laminate thickness, eliminating the heating variations that occur with thick single layers.
3Strength
If multiple substructures are used to support laminate layers, then structural support is provided, but warping and twisting occur during fabrication
Solution Approach 1:
The patent removes the intermediate mold from the final tool structure after it has served its purpose during laminate curing. The intermediate mold is extracted after the laminate is cured to the desired shape, leaving only the cured laminate as the final tool surface, thereby eliminating the need for multiple substructures and their associated alignment issues.
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 reduces fabrication time and costs, ensures faster and more uniform processing, and minimizes structural inaccuracies by using fewer substructures and thinner laminate layers, resulting in a more efficient and cost-effective composite tool production.
Implementation Method 1
The low temperature cured resin laminate is heated and compressed to form a cured low temperature cured resin laminate
Implementation Method 2
The high temperature cured resin laminate is heated and compressed to form a cured high temperature cured resin laminate
Data Source
AI summary
Methods for fabricating composite tools and composite tools are provided. In an exemplary embodiment, a method for fabricating a composite tool includes providing a master mold and forming a low temperature cured resin laminate overlying the master mold. The low temperature cured resin laminate is heated and compressed to form a cured low temperature cured resin laminate, the low temperature cured resin laminate heated to a first temperature. The cured low temperature cured resin laminate is removed from the master mold and a high temperature cured resin laminate is formed overlying the cured low temperature cured resin laminate. The high temperature cured resin laminate is heated and compressed to form a cured high temperature cured resin laminate. The high temperature cured resin laminate is heated to a second temperature, wherein the second temperature is higher than the first temperature.