Fluoroelastomer Coated Elastomeric Tooling for Composite Manufacturing
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Solution Overview
Problem
Conventional elastomeric tooling materials, such as silicone and EPDM, interact negatively with epoxy-based resin systems, leading to contamination, degradation, and limitations in mechanical properties, while fluoroelastomers offer chemical inertness but are expensive and difficult to repair, and fluoropolymer encapsulants cause delamination and wrinkles during composite manufacturing.
Innovation Solution
A tooling structure comprising a thin fluoroelastomer outer layer bonded with a base elastomer, such as silicone or EPDM, using an interface layer like VMQ silicone, allowing for cost-effective, flexible, and chemically inert tooling that avoids autoclave processing and reduces delamination and wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional elastomeric tooling materials (silicone, EPDM) are used, then cost and ease of manufacture are improved, but chemical compatibility with epoxy resin systems deteriorates leading to contamination and degradation
Solution Approach 1:
The tooling is divided into multiple layers with different materials: an inner layer of conventional elastomer (silicone or EPDM) for structural integrity and ease of manufacture, and an outer layer of fluoroelastomer for chemical compatibility with epoxy resin systems. This segmentation allows each layer to perform its optimal function without compromise
Solution Approach 2:
The invention uses a composite structure combining conventional elastomeric materials with fluoroelastomer materials. The composite provides both the manufacturing advantages of conventional materials and the chemical resistance of fluoroelastomers, resolving the contradiction between ease of manufacture and chemical compatibility
2Object-affected harmful factors
If fluoroelastomer is used for the entire tooling, then chemical inertness with epoxy resin systems is improved, but cost and difficulty of repair worsen
Solution Approach 1:
Instead of making the entire tooling from expensive fluoroelastomer, only the outer surface layer that contacts the epoxy resin is made of fluoroelastomer. The inner structural layers use more cost-effective conventional elastomers. This local application of fluoroelastomer provides chemical inertness where needed while reducing overall cost and improving repairability
Solution Approach 2:
The tooling is segmented into an outer fluoroelastomer layer for chemical resistance and inner conventional elastomer layers for structural support. This segmentation allows the expensive fluoroelastomer to be used only where chemically necessary, reducing overall cost while maintaining chemical inertness at the resin interface
3Object-affected harmful factors
If fluoropolymer encapsulants are used, then chemical protection is improved, but structural integrity deteriorates due to delamination and wrinkles
Solution Approach 1:
The invention uses a composite material system where fluoroelastomer and conventional elastomer are chemically bonded through co-curing processes. This creates a unified composite structure that maintains structural integrity while providing chemical protection, avoiding the delamination and wrinkle problems associated with physical encapsulation
Solution Approach 2:
The fluoroelastomer layer acts as an intermediary between the epoxy resin system and the inner conventional elastomer layers. It provides chemical protection while being chemically bonded to both the resin and the inner layer, preventing delamination and maintaining 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 solution provides a cost-effective, chemically inert, and mechanically robust elastomeric tooling that minimizes interactions with epoxy resin systems, reduces production costs, and prevents delamination and wrinkles, enabling efficient composite manufacturing without the need for autoclave processing.
Implementation Method 1
fluoroelastomers offer chemical inertness
Implementation Method 2
an elastomeric interface layer positioned between the elastomeric outer layer and the elastomeric inner layer. the elastomeric interface layer facilitates adhesion between the elastomeric outer layer and the elastomeric inner layer
Implementation Method 3
the elastomeric tooling is a bladder, the elastomeric inner layer substantially defines an inner cavity, and the elastomeric tooling can be expanded by applying a positive pressure to the inner cavity
Data Source
AI summary
A multi-layer elastomeric tooling for the manufacturing of composite structures is disclosed. The tooling comprises an elastomeric base material with an outer layer of fluoroelastomer. The base material can, in certain embodiments, be selected for its mechanical or thermal performance or low cost without the limitation of being a contact material. The outer material can, in various embodiments, have inferior mechanical properties, or durometers different than the base material or can be a contact or barrier material.