Deformable Spacer Resin Distribution in Fiber Composites
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Solution Overview
Problem
In the production of fiber composite components, high injection pressures during resin infusion can cause fiber mats to shift, leading to decreased load-bearing capacity and potential clogging, while existing methods to enhance infiltration speed often result in undesirable resin residue on the component surface.
Innovation Solution
The method involves introducing a fiber layer and spacers into a mold cavity, where the spacers create distribution channels for the resin to flow through, allowing for efficient resin distribution without the need for separate temporary channels, and are designed to deform and integrate into the final component, reducing fiber layer compaction and resin residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection pressure is increased to increase infiltration speed, then the rate of resin distribution is improved, but fiber mats shift and load-bearing capacity decreases
Solution Approach 1:
The tool cavity is divided into distribution channels and fiber reinforcement areas. The distribution channels are segmented pathways that guide resin flow separately from the fiber mats, allowing high-speed resin distribution without disturbing the fiber mats. This segmentation enables the resin to flow through dedicated channels rather than forcing its way through the fiber structure, thus maintaining fiber position stability while achieving high infiltration speed.
Solution Approach 2:
Distribution channels act as an intermediary structure between the resin injection point and the fiber reinforcement areas. These channels provide a dedicated pathway for resin flow, mediating the interaction between resin and fibers. The resin flows through the channels first, then impregnates the fibers from the channel outlets, preventing direct high-pressure resin-fiber interaction that would cause fiber displacement.
2Productivity
If distribution channels are provided in the tool to enable rapid resin distribution, then infiltration speed is improved, but resin remains in channels and hardens on component surface creating undesirable resin areas
Solution Approach 1:
The distribution channels are designed with variable cross-sections along their length. The channel geometry dynamically changes from wider inlet sections to narrower outlet sections, creating a flow velocity gradient. This dynamic geometry ensures that resin flows quickly through the channels for rapid distribution but slows down near the outlets, allowing complete impregnation of fibers and preventing resin pooling on the component surface.
Solution Approach 2:
The channel dimensions and flow parameters are optimized to control resin behavior. By adjusting channel width, depth, and length, the resin flow rate and pressure distribution are controlled. The parameters are designed so that resin velocity is high in the channel body for rapid transport but low at the outlets for complete fiber impregnation, eliminating resin residue while maintaining fast infiltration.
3Productivity
If tool is not completely closed during infiltration to allow rapid resin spread, then resin distribution speed is improved, but fiber material shifts due to high injection pressures
Solution Approach 1:
The tool cavity is segmented into pressurization zones and protection zones. The distribution channels are located in pressurization zones where high resin pressure is applied to drive rapid resin flow. The fiber reinforcement areas are located in protection zones where the tool remains closed to maintain confinement and prevent fiber shift. This spatial segmentation allows simultaneous high resin spread rate and fiber position stability.
4Productivity
If injection pressure is increased to overcome flow resistance through fiber material, then infiltration speed is improved, but fiber mats shift and cavity becomes clogged
Solution Approach 1:
The resin flow path is segmented into low-resistance distribution channels and high-resistance fiber impregnation zones. The distribution channels provide easy flow paths with minimal resistance, allowing high infiltration speed at low pressure. The fiber impregnation zones are designed with channel outlets positioned to allow resin to penetrate fibers gradually, reducing peak pressure requirements and preventing fiber mat shifting and cavity clogging.
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 enables high-speed resin infiltration with reduced risk of fiber displacement and eliminates the need for separate resin channels, resulting in improved resin distribution and reduced pressure requirements, enhancing the quality and efficiency of fiber composite part production.
Implementation Method 1
the spacer or spacers being deformed and the plastic material contained in the distribution channel or region flowing into the fiber layer
Data Source
Figure 1~4
Figure 5~9
Figure 10~13
AI summary
Method for producing a fiber composite part (1), wherein at least one fiber layer (10, 11) and a spacer (30, 33-35) or a plurality of spacers (30, 33-35) are introduced into a cavity of a mold (5, 5a, 6, 7), such that the spacers (30, 33-35) provide at least one distribution channel or area (15) for the plastic material to be injected, particularly adjacent to the fiber layer (10), and the plastic material is injected into the mold (5, 6, 7), and subsequently the cavity of the mold is brought to the dimensions of the fiber composite part, wherein the spacer(s) (30, 33-35) deform and the plastic material contained in the distribution channel or area (15) flows into the fiber layer (10, 11).