Curable prepregs with surface openings
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Solution Overview
Problem
Fiber-reinforced polymer composites face challenges in removing trapped gases during consolidation, leading to porosity issues that affect their mechanical properties, as traditional methods like edge breathers are inefficient in removing all gases.
Innovation Solution
The development of curable prepregs with resin-impregnated woven fabrics treated to create specific surface openings, allowing for enhanced gas removal through these openings during consolidation and curing, facilitating the escape of gases and reducing porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional consolidation methods are used, then the composite structure is simple, but gases are trapped inside prepregs and between layers resulting in porosity
Solution Approach 1:
The patent applies porous materials by incorporating through-thickness channels and void spaces within the prepreg structure. These channels create pathways for gas evacuation during consolidation, allowing trapped gases to escape from between prepreg layers and within the laminate, thereby reducing porosity and improving composite quality without requiring complex external equipment
Solution Approach 2:
The patent segments the continuous resin matrix by introducing discrete through-thickness channels that divide the consolidation space into separate regions. This segmentation creates multiple gas evacuation pathways, allowing gases to be removed from different locations simultaneously during consolidation, improving gas removal efficiency while maintaining a relatively simple overall structure
2Productivity
If edge breathers are used to remove gases, then some gas removal is achieved, but the process is slow and not all trapped gases are removed
Solution Approach 1:
The patent transitions from two-dimensional gas removal at the edges (edge breathers) to three-dimensional gas removal through through-thickness channels distributed throughout the prepreg. This dimensional change allows gas evacuation to occur simultaneously from multiple locations and depths within the laminate, dramatically improving gas removal efficiency and reducing consolidation time
Solution Approach 2:
The patent introduces through-thickness channels as intermediary pathways that facilitate gas transport from the interior of the prepreg stack to the surface. These channels act as mediators between the trapped gases and the external environment, enabling efficient gas removal without requiring complex external vacuum systems or extending consolidation time
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 use of curable prepregs with surface openings significantly reduces porosity in the final composite, improving its mechanical properties by enabling more effective gas removal during the consolidation process.
Implementation Method 1
heat may be applied to cause the matrix resin to flow, enabling consolidation of the prepreg layers
Implementation Method 2
Each curable prepreg is a resin-impregnated, woven fabric that has been treated to create an array of openings in at least one major surface
Data Source
AI summary
Curable prepregs possessing enhanced ability for the removal of gases from within prepregs and between prepreg plies in a prepreg layup prior to and/or during consolidation and curing. Each curable prepreg is a resin-impregnated, woven fabric that has been subjected to a treatment to create an array of openings in at least one major surface. Furthermore, the location of the openings is specific to the weave pattern of the fabric.