Fiber Preform Flow Paths for Resin Impregnation
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Solution Overview
Problem
Existing methods for producing composite components face limitations in achieving high material thickness due to poor soakability of fiber preforms, particularly in the thickness direction, leading to incomplete resin penetration and defects like pores and waviness.
Innovation Solution
Creating specific flow paths within the fiber preforms by modifying their structure with binders or wrapping with yarns at predetermined intervals, which enhances resin impregnation and reduces settling distances, allowing for thicker and more compact components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber preforms are made compact and dense to minimize settling, then laminate waviness is prevented, but impregnation difficulty increases significantly
Solution Approach 1:
The fiber preform structure is segmented into distinct regions: compact dense regions for structural integrity and less compact regions with flow paths for resin infiltration. This segmentation allows simultaneous achievement of laminate uniformity and impregnation ease by separating the functions of different preform regions.
Solution Approach 2:
Flow paths act as intermediary channels that facilitate resin transport through the compact preform structure. These pathways serve as mediators between the resin reservoir and the dense fiber regions, enabling impregnation without compromising preform compactness.
2Reliability
If excess resin is used in wet winding, then complete impregnation is achieved, but additional costs and laminate settling occur
Solution Approach 1:
Flow paths are created in the fiber preform during the preforming stage, before resin infiltration. This preliminary structuring of the preform ensures that resin will distribute uniformly during impregnation, eliminating the need for excess resin and preventing laminate settling caused by resin weight.
Solution Approach 2:
The flow paths utilize fluid dynamics principles to guide resin flow through the preform structure. By designing appropriate flow path geometry and orientation, resin infiltration is controlled to achieve complete impregnation with minimal resin volume, preventing both waste and settling issues.
3Length of stationary object
If fiber preform thickness is increased, then component thickness capability improves, but resin penetration to the base is prevented
Solution Approach 1:
Flow paths are introduced as a third-dimensional feature within the thick preform structure. These pathways extend through the thickness direction, creating channels that allow resin to reach the base of thick preforms. This dimensional addition solves the penetration problem without limiting preform thickness.
Solution Approach 2:
The preform structure incorporates porous or less compact regions along the flow paths that facilitate resin infiltration. These porous zones act as infiltration channels through the thick preform, enabling complete resin penetration to the base while maintaining overall preform structural integrity.
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 rapid and complete resin impregnation, reducing defects and improving process reliability, enabling the production of thicker components with higher fiber volume fractions and cost savings by expanding the resin infusion process applicability.
Implementation Method 1
flow paths for the liquid resin are specifically created in the fiber preforms
Implementation Method 2
resin infiltration
Data Source
AI summary
The present invention relates to the production of, in particular, rotationally symmetrical composite components which consist of dry preforms of reinforcing fibers and which are subsequently impregnated or infiltrated with liquid resin for forming a resin matrix. The present invention especially relates to the production of fiber preforms having an increased impregnation ability for liquid resin.