Fibre Composite Reinforcement with Elastic Core
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Solution Overview
Problem
Current methods for manufacturing fibre composite components with integrally designed stiffening profiles struggle to achieve optimal mechanical properties and weight efficiency, particularly in high-load applications like aircraft components, due to limitations in pressure distribution and material bonding during the manufacturing process.
Innovation Solution
A method involving the use of a supporting core with an elastic sleeve and hook-and-loop interfaces between fibrous material layers, allowing for a vacuum chamber to be formed and cured under high pressure in an autoclave, which enhances material compaction and bonding, while maintaining pressure equilibrium and facilitating weight reduction by removing the core post-curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional manufacturing methods with supporting bodies are used, then integral stiffening profiles can be formed, but the mechanical properties and weight efficiency are not optimal
Solution Approach 1:
The patent changes the physical state and parameters of the matrix material by injecting it under pressure into the fibrous material after vacuum evacuation, and then curing it under controlled temperature and pressure conditions in an autoclave. This parameter optimization achieves optimal mechanical properties while minimizing weight
Solution Approach 2:
The patent uses a composite structure combining fibrous material (reinforcement) with matrix material (resin), creating a fibre composite that optimizes the strength-to-weight ratio. The supporting core is temporarily removed after curing, leaving a hollow reinforcement section that further reduces weight while maintaining structural integrity
2Manufacturing precision
If vacuum chamber evacuation is performed, then material compaction is improved, but pressure distribution challenges arise
Solution Approach 1:
The vacuum chamber is evacuated before the autoclave curing process begins, preparing the fibrous material in advance by removing air and compacting it. This preliminary action ensures proper material preparation before the high-pressure curing stage, achieving both good compaction and pressure distribution
Solution Approach 2:
The manufacturing process uses sequential periodic actions: first vacuum evacuation for compaction, then pressure application in the autoclave for curing. This staged approach allows each process step to optimize its function without interfering with the other, achieving both material compaction and proper pressure distribution
3Strength
If hook-and-loop interfaces are used, then bonding between layers is enhanced, but manufacturing complexity increases
Solution Approach 1:
The hook-and-loop interfaces are integrated into the fibrous material itself during manufacturing, creating a permanent bonding mechanism that eliminates the need for separate adhesive applications or complex assembly steps. The interfaces are simple to implement and maintain while providing reliable bonding
4Weight of moving object
If supporting core is removed after curing, then weight is reduced, but manufacturing process time increases
Solution Approach 1:
The supporting core is designed to be temporarily positioned and then easily removed after curing. The fibrous material tube is pre-formed with hook-and-loop interfaces that maintain structural integrity during curing, allowing the core to be removed afterward without requiring additional reinforcement or assembly steps
Solution Approach 2:
The supporting core serves its purpose during manufacturing (providing structural support and defining the hollow section geometry) and is then discarded after curing. This temporary use allows weight reduction while maintaining structural integrity during the critical curing phase
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 enables the production of fibre composite components with improved mechanical properties and reduced weight, enhanced impact resistance, and minimized peeling effects, suitable for high-load applications by ensuring effective compaction and bonding through the use of hook-and-loop interfaces and high-pressure curing.
Implementation Method 1
evacuation of the vacuum chamber
Implementation Method 2
curing of the fibrous material
Implementation Method 3
cured under high pressure in an autoclave
Implementation Method 4
hook-and-loop interfaces in their reciprocal bonding regions to provide a form-fit connection
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention concerns in the first instance a method for the manufacture of a reinforcement section 24 of a fibre composite component 94, which bounds a cavity 96, whereby a supporting core 40, with an elastic sleeve 42 bounding an interior space 44, is temporarily positioned in the cavity 96, with the steps: a) laying down of fibrous material 10 on a base moulding tool 12 to form a base element 14 of the fibre composite component 94, b) draping of fibrous material 10 in a negative mould 26, c) arrangement of the supporting core 40 on an inner surface 66 of the fibrous material 10 of the reinforcement section 24 in the negative mould 26, d) positioning of the negative mould 26, fitted with the fibrous material 10 and the supporting core 40, on the base element 14 to form the reinforcement section 24, e) forming of a vacuum chamber 60 accommodating the negative mould 26 and the base element 14 by covering by means of a vacuum film 58, f) evacuation of the vacuum chamber 60, and g) curing of the fibrous material 10, whereby when using a dry fibrous material 10 a matrix material, in particular a resin material 90, is injected into the fibrous material 10 after the evacuation. In addition the invention has as its subject a supporting core 40 for the execution of the method, and also a fibre composite component 94 produced in accordance with the method.