Deformable Mold Tool Peristaltic Actuation Composite Infusion
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Solution Overview
Problem
Existing liquid moulding processes for composite components require high pressures due to high viscosity of matrix materials and low permeability of fibre preforms, leading to increased energy consumption, component porosity, and fibre disruption, limiting the size and quality of manufactured components.
Innovation Solution
The use of a deformable mould tool with peristaltic actuators and a flexible interface layer generates a peristaltic pressure wave to facilitate the flow of viscous matrix materials through the mould cavity, reducing the pressure gradient and fibre disruption, while a control system manages infusion and curing to optimize fibre volume fraction and component quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high pressure is applied to force matrix material through the mould cavity, then the matrix material can be forced through the fibre preform, but energy consumption increases and fibre disruption occurs
Solution Approach 1:
The mould tool is designed to be deformable rather than rigid, allowing it to dynamically adapt its shape during the matrix material infusion process. The mould tool deforms under pressure to conform to the fibre preform geometry, reducing the pressure gradient required and minimizing fibre disruption while maintaining infusion effectiveness
Solution Approach 2:
The invention changes the physical state and properties of the mould tool from rigid to deformable, allowing it to undergo shape changes during the molding process. This parameter change enables the mould tool to better accommodate the fibre preform and reduce the energy required for matrix material infusion
2Productivity
If high pressure is applied to force matrix material through the mould cavity, then the matrix material can be forced through the fibre preform, but fibre disruption and distortion increase
Solution Approach 1:
The deformable mould tool dynamically adjusts its shape during the infusion process, allowing the matrix material to flow through the fibre preform without excessive pressure. This dynamic deformation reduces fibre distortion and maintains fibre alignment while still achieving complete infusion
Solution Approach 2:
The deformable mould tool acts as a cushioning element that absorbs excess pressure and distributes it evenly during the infusion process. This beforehand cushioning effect prevents sudden pressure spikes that would cause fibre disruption and distortion
3Adaptability or versatility
If the mould cavity is made larger to accommodate complex components, then more complex components can be manufactured, but the pressure gradient increases and fill quality deteriorates
Solution Approach 1:
The deformable mould tool allows the mould cavity to effectively change its geometry during the infusion process. The tool deforms to conform to the specific fibre preform configuration, creating localized pressure zones that improve fill quality in complex geometries without requiring excessively large overall cavity sizes
Solution Approach 2:
The deformable mould tool creates locally adapted pressure distributions that match the specific requirements of different regions within the mould cavity. This local quality adjustment allows complex component geometries to be filled uniformly without requiring uniformly high pressure throughout the entire cavity
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 reduces the pressure required for matrix material infusion, minimizes fibre distortion, and enhances component quality by ensuring even pressure distribution and controlled fibre alignment, allowing for larger and more complex composite components to be manufactured with lower energy consumption and reduced unit costs.
Implementation Method 1
at least two peristaltic actuators, mounted to contact the interface layer and to generate a peristaltic pressure wave in the mould tool
Data Source
AI summary
Apparatus 200 for forming a composite component is disclosed, the apparatus comprising: a deformable mold tool 204 that at least partially defines a mold cavity 212; an interface layer 222 formed on an external surface of the mold tool 204; and at least two peristaltic actuators 206, mounted to contact the interface layer 222 and to generate a peristaltic pressure wave in the mold tool 204. The peristaltic actuators comprise rollers 206, pistons 306 or bi-metallic blocks 406. A method of forming a composite component is also disclosed, the method employing a mold tool 204 that at least partially defines a mold cavity 212. The method comprises: placing reinforcing fibers into the mold cavity 212, forcing a matrix material into the mold cavity 212 through the reinforcing fibers, and generating a peristaltic pressure wave within the mold tool 204 during forcing of the matrix material into the mold cavity 212.