Expandable Pellets for Uniform Composite Curing Pressure
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Solution Overview
Problem
The fabrication of composite parts faces challenges in applying even pressure during the curing process, especially with complex shapes or cavities, where traditional tooling is difficult to remove and may not apply uniform pressure effectively.
Innovation Solution
A system using expandable pellets or media with a polymer matrix and flexible skin, which can be charged with a blowing agent to expand and apply omnidirectional pressure to the composite part, allowing for easier shaping and removal, and can be reused by recharging the blowing agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tooling is used to press and hold the preform, then structural strength is maintained during curing, but the tooling is difficult to remove and cannot apply even pressure to complex shapes or cavities
Solution Approach 1:
The patent employs expandable pellets that transition from a compact state to an expanded state during curing. This dynamic transformation allows the pellets to adapt to complex geometries and apply uniform pressure throughout the preform, while the expanded state enables easy removal after curing completes
Solution Approach 2:
The pellets undergo parameter changes by expanding in volume and changing density during the curing process. This parameter transformation allows the same material to serve dual functions: applying precise pressure during curing and facilitating easy removal afterward, resolving the contradiction between manufacturing precision and ease of operation
2Force
If traditional rigid tooling is used, then pressure can be applied to the preform, but it cannot effectively reach complex shapes or cavities
Solution Approach 1:
The patent divides the tooling function into numerous individual expandable pellets rather than using a single rigid structure. This segmentation allows each pellet to independently adapt to complex geometries while collectively providing uniform pressure distribution across the entire preform surface
Solution Approach 2:
The expandable pellets dynamically change volume and shape to conform to complex geometries. This dynamic adaptability enables the pellets to reach into cavities and complex shapes that rigid tooling cannot access, while maintaining effective pressure application
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 method ensures even pressure application during curing, maintains the desired shape of composite parts with complex geometries, and facilitates easier removal of the tooling, while allowing for multiple uses of the expandable media by recharging the blowing agent.
Implementation Method 1
charged with a blowing agent to expand and apply omnidirectional pressure
Implementation Method 2
the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core
Data Source
AI summary
A material system including a plurality of expandable pellets or a monolithic flexible carrier is disclosed, each of which may include a polymer matrix configured to hold an expandable core, and a flexible skin configured to encapsulate the polymer matrix, and where the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core. Implementations of the material system may include where the polymer matrix may include a thermoplastic polymer. The material system may include a charging source configured to introduce blowing agent. A method of curing a composite part is also described.