Degradable Flow Medium for Resin Transfer Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing resin transfer molding processes, such as VARTM, face challenges with high viscosity resins and labor-intensive use and removal of non-degradable flow media, which increase production costs and complexity.
Innovation Solution
A degradable flow medium made from materials like polyvinyl butyral or polystyrene, which can be dissolved or melted during the curing process, is integrated into the composite component, eliminating the need for post-processing removal and absorption of resin, allowing for faster resin infusion and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a non-degradable flow medium is used to assist resin transfer, then resin injection speed is improved, but labor-intensive removal and resin absorption disposal are required
Solution Approach 1:
The flow medium's chemical composition is changed from non-degradable to degradable, allowing it to break down after serving its purpose. This parameter change enables the flow medium to maintain its structural integrity during resin injection while automatically decomposing afterward, eliminating manual removal efforts
Solution Approach 2:
The flow medium is designed as a temporary, disposable component that serves its function during the molding process and then degrades naturally. This approach replaces expensive, reusable flow media that require labor-intensive removal and cleaning with a cheaper, single-use alternative that eliminates post-processing operations
2Manufacturing precision
If a flow medium is used to distribute resin, then resin distribution is improved, but the flow medium absorbs resin that must be discarded
Solution Approach 1:
The chemical parameters of the flow medium are modified to change its interaction with resin from absorption to degradation. The degradable flow medium breaks down into harmless byproducts that can be easily removed, preventing resin entrapment and eliminating the need to discard absorbed resin
Solution Approach 2:
The flow medium's interaction with resin is transformed from a harmful absorption effect (trapping resin that must be discarded) to a beneficial degradation effect (breaking down the flow medium itself). This converts the problem of resin loss into an advantage where the flow medium disappears without retaining resin
3Ease of operation
If degradable flow medium is used, then post-processing is eliminated, but the flow medium must be compatible with resin curing
Solution Approach 1:
The degradation parameters of the flow medium are carefully selected to ensure compatibility with the resin curing process. The flow medium degrades at a rate and under conditions that do not interfere with resin polymerization, maintaining structural integrity when needed and decomposing safely afterward
Solution Approach 2:
The degradable flow medium acts as an intermediary between the mold cavity and the final composite part. It temporarily occupies space to enable proper resin flow and distribution, then mediates its own removal through degradation, leaving no harmful residues in the final product
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 degradable flow medium simplifies the production process by becoming part of the final composite component, reducing labor and costs associated with resin absorption and post-processing, while ensuring health and safety by avoiding contact with newly cured materials.
Implementation Method 1
the flow medium is made from a material which can be degraded and/or dissolved by the resin and/or by a temperature rise which occurs during the curing reaction of the resin
Implementation Method 2
the flow medium becomes a part of the final composite component at the latest during the last steps of composite component manufacture
Data Source
AI summary
A flow medium for assisting a resin to be transferred into a mold accommodating a layered structure of reinforced material is provided. The flow medium is configured such that when the resin is cured the flow medium becomes incorporated within a final composite component comprising the reinforced material embedded within the transferred and cured resin. A semifinished product comprising such a flow medium is provided and a method for producing a composite component by utilizing such a semifinished product is also provided.