Deformable Mandrel for Complex Composite Structures
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Solution Overview
Problem
The complexity of forming composite components with complex shapes often requires multi-piece mandrels or additional bulk layers, which reduce fiber volume fraction and necessitate additional processing steps.
Innovation Solution
A deformable mandrel is used that maintains its original shape until the composite laminate is sufficiently rigid, allowing for complex shapes to be formed without the need for multi-piece mandrels or excessive bulk, and enabling easy extraction after curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multi-piece mandrels are used to form complex shapes, then the ability to create complex geometries is improved, but the device complexity and manufacturing process complexity increase
Solution Approach 1:
The mandrel is designed with a deformable portion that can change its shape or volume in response to environmental conditions (temperature, pressure, chemical exposure). This dynamic capability allows a single-piece mandrel to achieve complex geometries that would otherwise require multi-piece assemblies, thereby reducing mandrel complexity while maintaining complex shape formation capability
Solution Approach 2:
The mandrel material properties are changed in response to environmental conditions during the composite manufacturing process. By adjusting parameters such as temperature, pressure, or chemical exposure, the mandrel's physical state (rigid/deformable, volume, shape) is modified to enable extraction from complex geometries without requiring complex multi-piece designs
2Shape
If additional bulk layers are added to form complex shapes, then the shape formation capability is improved, but the fiber volume fraction decreases
Solution Approach 1:
Instead of adding bulk layers to achieve complex shapes, the mandrel itself is modified through parameter changes (deformation, melting, dissolving) to create the necessary geometry. This approach forms complex shapes by removing or deforming mandrel material rather than adding composite bulk, thereby maintaining high fiber volume fractions in the final product
3Ease of manufacture
If the mandrel is made removable before deformation, then the extraction process is simplified, but the ability to maintain complex shapes during curing is compromised
Solution Approach 1:
The mandrel transitions from a rigid state during curing (maintaining shape fidelity) to a deformable state for extraction. The deformable portion is designed to remain intact and functional during the curing process, then deform or dissolve after curing to enable simple extraction, thus achieving both shape fidelity and ease of removal
4Device complexity
If single-piece mandrels are used, then the manufacturing process is simplified, but the extraction from complex geometries becomes difficult
Solution Approach 1:
The mandrel is designed as a single-piece structure with a deformable portion that undergoes parameter changes (phase transition, dissolution, deformation) after the composite cures. This allows the simple single-piece mandrel to be easily extracted from complex geometries through controlled material property changes, combining structural simplicity with extraction ease
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 allows for the formation of complex composite structures with increased fiber volume fractions, reduces the risk of wrinkles and microcracking, and simplifies the manufacturing process by eliminating the need for complex mandrels and additional processing steps.
Implementation Method 1
Gelation of the infused resin is caused by applying a first environmental condition to the composite laminate and mandrel
Implementation Method 2
At least a portion of the mandrel is deformed by applying a second environmental condition to the composite laminate and mandrel
Implementation Method 3
The second environmental condition is an increased pressure above a pressure applied during gelation of the infused resin
Implementation Method 4
forming a composite structure by curing the composite laminate infused with resin
Data Source
AI summary
A method for forming composite components includes disposing composite laminate over a mandrel. The method further includes infusing the composite laminate with a resin. A gelation of the infused resin is caused by applying a first environmental condition to the composite laminate and mandrel. At least a portion of the mandrel is deformed by applying a second environmental condition to the composite laminate and mandrel. The method further includes forming a composite structure by curing the composite laminate infused with resin. The deformed mandrel is removed from the composite structure after forming the composite structure.