Cork-Based Mould Core for Aerospace Fibre Composite Components
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Solution Overview
Problem
Current methods for producing fibre composite components, particularly in the aerospace industry, face challenges with reproducibility, cost, weight, and quality due to the use of traditional supporting cores, which can result in porous laminates, unsatisfactory adhesions, and increased material costs, especially when using silicone rubber or polyamide materials.
Innovation Solution
A mould core formed from cork material is used to support and shape fibre composite components, allowing for multi-stage heat and pressure application, providing a cost-effective, lightweight, and dimensionally stable solution that can be reused and recycled, while also offering acoustic muffling and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional supporting cores (silicone rubber or polyamide) are used, then the fibre composite component can be produced, but the component quality is poor with porous laminates and unsatisfactory adhesively bonded joints
Solution Approach 1:
The patent changes the material parameters of the supporting core from traditional silicone rubber or polyamide to a specifically formulated composite material containing rubber granulates (10-50 mesh size), cork dust (10-50 mesh size), and binder resin. This material parameter change eliminates tube bursters, prevents porous laminates, and ensures reproducible adhesion quality without requiring post-curing modifications.
Solution Approach 2:
The supporting core uses a composite material formulation combining rubber granulates, cork dust, and binder resin in specific proportions. This composite structure provides both the necessary mechanical support during curing and the surface properties for optimal adhesion, resolving the contradiction between structural integrity and bonding quality.
2Ease of manufacture
If hollow profiled parts made of silicone rubber are used as supporting cores, then the component can be produced, but the material costs are high and the immobilisation time is short
Solution Approach 1:
The patent modifies the material composition and physical properties of the supporting core to extend immobilisation time from minutes to hours. The composite material with rubber granulates, cork dust, and binder resin maintains dimensional stability and structural support throughout the entire curing process, eliminating the need for rapid immobilisation required by traditional silicone rubber cores.
Solution Approach 2:
The supporting core material can be applied directly to the substrate and remains in place throughout curing without requiring expensive hollow profiled structures. The material is cost-effective and can be easily removed after curing, eliminating the need for complex reusable molds or expensive silicone rubber profiles.
3Reliability
If traditional supporting cores are used, then the fibre composite component can be produced, but the cores can only be removed with difficulty and material remains in the stringers increasing weight
Solution Approach 1:
The supporting core material is designed to be easily removable from the cured fibre composite component. The composite formulation allows clean separation without leaving residual material in the stringers or bonding areas, eliminating the weight penalty associated with traditional supporting core materials that leave behind film inclusions or require forceful removal.
Solution Approach 2:
The material properties of the supporting core are optimized to provide easy removal after curing. The composite material with rubber granulates, cork dust, and binder resin creates a surface that releases cleanly from the cured composite, ensuring no material remains in the stringers and the aircraft weight is minimized.
4Stress or pressure
If profiled tubular films or silicone profiled parts are used as supporting cores, then the autoclave pressure can be transmitted, but the supporting cores do not always result in reproducible component quality
Solution Approach 1:
The patent changes the material parameters of the supporting core to achieve consistent, reproducible component quality. The composite material with rubber granulates, cork dust, and binder resin provides uniform pressure distribution and maintains stable physical properties throughout the curing process, eliminating the variability and tube bursters associated with traditional profiled tubular films and silicone profiles.
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 cork-based mould core enhances the quality and cost-effectiveness of fibre composite components by ensuring better adhesion, reducing material waste, and providing improved acoustic and thermal performance, leading to enhanced structural integrity and reduced weight.
Implementation Method 1
providing acoustic muffling and thermal insulation
Implementation Method 2
providing acoustic muffling and thermal insulation
Data Source
AI summary
A method for producing a fiber composite component, in particular for aerospace, the method comprising the following steps: forming a mold core from a material comprising cork by a molding tool to establish an outer geometry of said mold core; arranging the so formed mold core adjacent to an at least partly hardened stiffening element on a base element of said composite component to be produced for the shaping of at least one molded portion of said fiber composite component to be produced; and multistage exposure of at least said molded portion to heat and/or pressure to produce said fiber composite component; a corresponding mold core and a corresponding fiber composite component.