Deformable Flow Media for Complete Resin Infusion in Complex Preforms
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Solution Overview
Problem
Current resin infusion methods for composite structures face challenges in ensuring uniform resin flow across complex preform geometries, leading to incomplete infusion and deficient composite components due to the mechanical nature of traditional valves and the need for laborious cleaning and assembly.
Innovation Solution
An actuatable flow media system with an elastically deformable element and flexible membrane is used to control resin flow rate by selectively opening and closing apertures, allowing for precise regulation of resin infusion into composite preforms, eliminating the need for traditional valves and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical resin inlet valve is used to control resin flow rate, then the flow rate can be controlled, but the valve becomes filled with resin and requires time-consuming disassembly and cleaning between uses
Solution Approach 1:
The patent employs a consumable flow media (permeable fabric or mesh) that is discarded after a single use rather than reused. This eliminates the time-consuming cleaning and disassembly of mechanical valves between resin infusion processes, as the flow media is replaced with a fresh component for each cycle, directly resolving the time loss issue while maintaining ease of operation through simple replacement procedures
Solution Approach 2:
The invention extracts the flow control function from the mechanical valve system and transfers it to the permeable flow media. By removing the resin inlet valve entirely and using the permeable media's inherent porosity to control resin flow rate, the system eliminates the contamination and cleaning issues associated with mechanical valves while maintaining effective flow regulation
2Ease of manufacture
If resin infusion is performed without flow control media, then the process is simpler, but resin does not fill complex preform geometries completely resulting in deficient composite components
Solution Approach 1:
The patent introduces a permeable flow media as an intermediary component between the resin supply and the composite preform. This media acts as a mediator that distributes resin flow evenly across the preform surface, ensuring complete penetration into complex geometries and difficult-to-reach areas while maintaining the overall simplicity of the manufacturing process
Solution Approach 2:
The permeable flow media provides locally adapted flow distribution characteristics, with different regions of the media allowing different flow rates based on the local preform geometry and permeability requirements. This ensures uniform resin saturation throughout the entire preform, including areas with varying thickness or fiber density, thereby achieving high manufacturing precision without complicating the overall process
3Productivity
If traditional mechanical valves are used for resin flow control, then flow rate can be regulated, but the valves are complex and require thorough cleaning and assembly procedures
Solution Approach 1:
By replacing complex mechanical valves with a simple consumable permeable flow media, the system dramatically reduces device complexity. The flow media consists of basic permeable materials like fabric or mesh that require no moving parts, seals, or adjustment mechanisms, thereby eliminating the complexity issues while improving productivity through rapid replacement instead of cleaning and reassembly procedures
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 solution ensures consistent and complete resin infusion across complex geometries, reducing labor and equipment costs by using a consumable, easily replaceable flow media that controls resin flow rate effectively, resulting in high-quality composite components.
Implementation Method 1
an elastically deformable element arranged in the cavity and extending between the base and the flexible membrane for actuation between at least a first configuration in which the elastically deformable element is substantially undeformed and the liquid flow path through the at least one aperture is open and a second configuration in which the elastically deformable element is substantially deformed and the liquid flow path through the at least one aperture is closed
Implementation Method 2
Resin is infused through the composite preform by application of vacuum pressure to a downstream end of the sealed chamber, drawing resin from an upstream resin supply through the composite preform
Data Source
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AI summary
An actuatable flow media (170) for the control of a flow rate of a liquid through the flow media, the actuatable flow media (170) comprising a base (171) having at least one cavity (172) formed therein, at least one aperture (174) formed in the cavity (172) defining a liquid flow path for the entry of liquid into or exit of liquid from the flow media; a flexible membrane (190) arranged in spaced relation with the base (171) and defining a liquid flow path through the flow media; and an elastically deformable element (180) arranged in the cavity (172) and extending between the base (171) and the flexible membrane (190) for actuation between at least a first configuration in which the capsule (180) is substantially undeformed and the liquid flow path through the at least one aperture (174) is open and a second configuration in which the element (180) is substantially deformed and the liquid flow path through the at least one aperture (174) is closed.