In-situ Fluorescent Imaging for Liquid Composite Molding
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Solution Overview
Problem
Sub-optimal fluid flow and bubble formation in liquid composite molding processes limit the mechanical properties of composites, hindering the increased adoption of these processes.
Innovation Solution
In-situ data acquisition method using a transparent mold with ultraviolet lighting and fluorescent dye, capturing images of fluid flow, and processing them to analyze fluid and bubble-related information through image filtering and measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional LCM processes are used without in-situ monitoring, then the manufacturing process is simpler and faster, but the mechanical properties of composites are limited due to sub-optimal fluid flow and bubble formation
Solution Approach 1:
The patent applies fluorescent dye to the fluid and uses ultraviolet lighting to create visual contrast, enabling the camera to detect fluid flow patterns and bubble formation. This color change technique transforms invisible fluid dynamics into visible data without altering the fundamental LCM process.
Solution Approach 2:
The transparent mold acts as an intermediary that allows optical access for imaging while containing the fluid flow process. The fluorescent dye serves as another intermediary that enables visualization of fluid behavior without affecting the composite material properties.
2Measurement precision
If a transparent mold with imaging system is implemented, then fluid flow and bubble formation can be characterized, but the device complexity and cost increase
Solution Approach 1:
Fluorescent dye is added to the fluid to enhance contrast under ultraviolet lighting, enabling precise visualization and measurement of fluid flow patterns and bubble formation. This optical enhancement technique improves measurement precision without requiring complex sensor arrays.
Solution Approach 2:
The imaging system creates visual copies (images) of the fluid flow and bubble formation processes, which can then be analyzed digitally. This allows precise measurement of fluid dynamics through image processing rather than direct physical measurement.
3Measurement precision
If image processing with multiple filtering steps is applied, then bubble related information can be accurately measured, but the processing time and computational complexity increase
Solution Approach 1:
The image processing methodology segments the analysis into distinct filtering stages: green filter application, binarization, pixel grouping, orientation filtering, and bubble measurement. This segmentation allows systematic processing of different image features in sequence, improving measurement precision through staged analysis.
Solution Approach 2:
The processing pipeline applies multiple filtering steps beyond what might be minimally necessary, including orientation filtering and aspect ratio filtering, to ensure high precision in bubble characterization. This excessive action ensures that only relevant features are measured, improving accuracy despite increased processing time.
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
Enhances the characterization of fluid flow and bubble formation, allowing for improved control and optimization of liquid composite molding processes, thereby enhancing the mechanical properties of the composites.
Implementation Method 1
injecting a fluid into the cavity of the mold, the fluid comprising a fluorescent dye, lighting the mold with an ultraviolet lighting source
Data Source
AI summary
A method for in-situ data acquisition comprises providing a mold, wherein at least a portion of the mold is transparent, inserting a liquid composite molding reinforcement into a cavity of the mold, injecting a fluid into the cavity of the mold, the fluid comprising a fluorescent dye, lighting the mold with an ultraviolet lighting source and capturing a plurality of images of a front portion of the fluid as the fluid advances within the cavity of the mold. Capturing the plurality of images of a front portion of the fluid may include advancing a camera along a camera track as the fluid advances within the cavity of the mold. A corresponding method and computer program product for processing images captured by the above method are also disclosed herein.