Cure Tool Integrated Edge Breather for Composite Layup
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Solution Overview
Problem
Consumable edge breather materials used in composite part curing are costly and prone to compression, reducing their effectiveness in evacuating air and volatiles during the curing process.
Innovation Solution
An integrated edge breather is formed into the surface of a cure tool, comprising a network of recessed channels and passageways that connect to a vacuum source, allowing for consistent air removal without the need for consumable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If consumable breather materials are used, then air and volatiles can be evacuated from the layup, but the materials compress under bag force reducing breathing volume and require costly replacement
Solution Approach 1:
The breather function is merged with the cure tool itself by forming channels directly into the tool surface. This integration eliminates the need for separate consumable breather materials while maintaining the air evacuation function throughout the curing process.
Solution Approach 2:
The cure tool provides its own breather function through integrated channels, eliminating dependency on external consumable materials. The tool serves dual purposes: curing the composite and facilitating air/volatile removal through its built-in channel network.
2Productivity
If consumable breather materials are used, then edges can breathe during curing, but repeated replacement is required increasing labor and material costs
Solution Approach 1:
The breather functionality is combined with the cure tool structure, creating a permanent integrated system that eliminates the need for repeated installation and replacement of separate breather materials across multiple curing cycles.
Solution Approach 2:
The integrated channels provide sufficient breathing capacity without requiring replacement, effectively performing the breather function excessively well by being permanent rather than consumable, thus eliminating replacement needs entirely.
3Object-generated harmful factors
If consumable breather materials are used, then air evacuation is achieved, but the materials are costly and require labor for replacement
Solution Approach 1:
The air evacuation function is merged into the cure tool's structure through integrated channels, eliminating the need for separate breather materials and the associated installation and replacement labor while maintaining effective air and volatile removal.
4Volume of moving object
If consumable breather materials are used, then edges can breathe, but the volume of breathing space reduces under applied bag force
Solution Approach 1:
The breather function is merged with the rigid cure tool structure, providing compression-resistant channels that maintain constant breathing volume even under high bag force, unlike compressible consumable materials.
Solution Approach 2:
The breather system transitions from using compressible consumable materials to rigid integrated channels, fundamentally changing the physical state and compressibility parameter to maintain constant breathing volume under load.
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 integrated breather provides a constant, large volume for air and volatile evacuation, enhancing airflow and reducing material costs by eliminating the need for disposable breather materials, especially at higher curing pressures.
Implementation Method 1
a vacuum in the bag may help remove entrapped air and volatiles from the layup
Implementation Method 2
at least one passageway in the tool body that is coupled with the network of channels and is adapted to be connected with a vacuum source for drawing air away from the edges of the layup through the channels
Data Source
AI summary
A tool for curing a composite layup comprises a tool body having a surface adapted to support a composite layup thereon. The tool includes an integrated breather for allowing removal of air from the layup during curing.