Expanded Polymer Tooling Recovery for Out-of-Autoclave Curing
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Solution Overview
Problem
The manufacturing process of composite materials using autoclaves creates bottlenecks due to throughput limitations and material transport requirements, necessitating an alternative curing method that maintains quality without traditional autoclave treatment.
Innovation Solution
Methods for recycling expanded polymer tooling by collecting, reducing, and purifying polymer compositions from out-of-autoclave manufacturing, including steps such as expanding pellets, applying directed fluid flow, and using heating, degassing, solvent cleaning, and phase separation to produce reusable polymer pellets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional autoclave curing is used for composite materials, then curing quality is maintained, but manufacturing throughput is limited and material transport requirements increase
Solution Approach 1:
The patent changes the curing parameters by transitioning from autoclave-based high-pressure high-temperature curing to a two-stage process: initial curing at lower pressure/temperature followed by post-curing at elevated temperature. This parameter modification enables improved throughput while maintaining composite quality, resolving the contradiction between curing quality and manufacturing productivity
Solution Approach 2:
The curing process is segmented into distinct stages: initial curing in a constrained mold, removal of constraints, and post-curing in an oven. This segmentation allows different portions of the manufacturing process to be optimized independently, enabling parallel processing and improved throughput while maintaining the quality standards traditionally achieved only in autoclaves
2Adaptability or versatility
If expandable polymer pellets are used for out-of-autoclave curing, then manufacturing flexibility is improved, but polymer material recovery becomes necessary to reduce waste
Solution Approach 1:
The patent implements a recovery system for expandable polymer pellets after they have been used for out-of-autoclave curing. The spent pellets are collected, processed to remove contaminants and decomposition products, and reused for subsequent curing operations. This recovery process eliminates polymer material waste while maintaining the manufacturing flexibility benefits of OOA curing
Solution Approach 2:
The patent converts the potentially harmful waste product (spent polymer pellets) into a reusable resource. By implementing processing steps that remove contaminants and restore the polymer to a usable state, the system transforms waste into a beneficial material that can be repeatedly reused, thereby eliminating the loss of substance while preserving the adaptability of OOA manufacturing
3Productivity
If expandable polymer pellets are expanded to apply pressure during curing, then out-of-autoclave manufacturing is enabled, but the polymer pellets require processing and purification for reuse
Solution Approach 1:
The processing system is segmented into distinct functional units: collection apparatus, processing chamber with heating and agitation, filtration system, and drying apparatus. This segmentation allows each function to be optimized independently and enables modular scaling, reducing the perceived complexity while maintaining high manufacturing efficiency
Solution Approach 2:
The processing apparatus is designed with multi-functional capabilities: the same system performs heating, mechanical agitation, filtration, and drying in sequence. This universality reduces equipment complexity compared to having separate dedicated equipment for each function, while still achieving thorough polymer purification and preparation for reuse, thereby maintaining high manufacturing efficiency
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
Facilitates efficient recycling and reuse of polymer materials for out-of-autoclave composite manufacturing, reducing material waste and optimizing production efficiency by reusing expanded polymer tooling.
Implementation Method 1
An expandable element can be configured to expand when a predetermined change is produced in the expandable element, typically a change in a physical property or chemical property of the expandable element. Where the expandable element is used in the form of a plurality of expandable pellets, the expandable pellets can be configured to undergo volumetric expansion when heated to at least a predetermined foaming temperature.
Implementation Method 2
The reduced particles can then be subjected to a purification treatment that can include heating, degassing, solvent treatment, phase separation, and/or filtration, for example, in order to remove one or more blowing agents from the polymer composition.
Implementation Method 3
The reduced particles can then be subjected to a purification treatment that can include heating, degassing, solvent treatment, phase separation, and/or filtration, for example, in order to remove one or more blowing agents from the polymer composition.
Implementation Method 4
The reduced particles can then be subjected to a purification treatment that can include heating, degassing, solvent treatment, phase separation, and/or filtration, for example, in order to remove one or more blowing agents from the polymer composition.
Data Source
AI summary
Methods of recovering and/or recycling expanded polymer tooling, the methods including collecting expanded polymer tooling, reducing the collected expanded polymer tooling into smaller particles, treating the reduced expanded polymer tooling in order to yield an at least partially purified recovered polymer composition, and then collecting the at least partially purified recovered polymer composition. The at least partially purified recovered polymer composition can then be used to form new expandable polymer tooling.