Foamable Layer for Hollow Composite Structure Manufacturing
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Solution Overview
Problem
Hollow composite structures currently require air bladder structures for internal pressure, increasing manufacturing time and material usage, which is inefficient.
Innovation Solution
The use of foamable layers in direct contact with fiber and resin matrix material layers within a mold, allowing the foamable material to expand and fill hollow sections without the need for air bladders, utilizing temperature-activated expansion to shape and cure the composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If air bladder structures are used to supply internal pressure for hollow composite structure manufacturing, then the composite structure can be formed with proper pressure, but manufacturing time increases and additional materials are required
Solution Approach 1:
The patent removes the air bladder structure from the manufacturing process entirely. Instead of using a separate air bladder to supply internal pressure, the invention uses the foamable material itself to generate the necessary pressure through its expansion process, eliminating the need for additional air bladder components and reducing manufacturing steps.
Solution Approach 2:
The patent combines the functions of the air bladder (pressure supply) and the core formation material into a single foamable material layer. This foamable layer simultaneously serves as the core structure and the pressure-generating element through its expansion, merging multiple functions into one component.
2Manufacturing precision
If air bladder structures are used to supply internal pressure, then hollow composite structures can be manufactured, but additional manufacturing materials and processes are required
Solution Approach 1:
The patent extracts and eliminates the air bladder structure from the material list. The foamable material replaces the air bladder's function without requiring the additional materials that would be needed for air bladders, their installation, and their removal or integration into the final product.
Solution Approach 2:
The foamable material layer serves multiple functions: it acts as the core structure, generates internal pressure through expansion, and forms the hollow section. This multi-functionality eliminates the need for separate air bladder materials and reduces the overall material list.
3Productivity
If foamable material layers are used to eliminate air bladders, then manufacturing time and materials are reduced, but the foamable material must expand uniformly to maintain structural integrity
Solution Approach 1:
The patent applies different properties to different parts of the foamable material system. The foamable material layer is positioned in specific locations (between outer and inner foamable layers) with controlled thickness and composition to ensure uniform expansion. The sandwich structure with varying layer properties ensures that expansion occurs uniformly throughout the hollow section.
Solution Approach 2:
The patent uses a composite structure consisting of multiple foamable material layers (outer, inner, and intermediate) with different properties. This composite approach allows control over expansion characteristics, ensuring uniform expansion while maintaining structural integrity. The combination of different foamable layers creates a balanced system that expands uniformly.
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 significantly reduces manufacturing time and materials by eliminating the need for air bladders, enabling efficient formation of hollow composite structures with improved mechanical properties and complex shapes.
Implementation Method 1
The foamable material layer may have a first expansion upon exposure to a first temperature and a second expansion upon exposure to a second temperature
Implementation Method 2
a fiber and resin matrix material layer at least partially forming a hollow section of the structure
Data Source
AI summary
A structure comprising: (i) a fiber and resin matrix material layer at least partially forming a hollow section of the structure; and (ii) a foamable material layer in direct planar contact with the fiber and resin matrix material layer, the foamable material layer at least partially filling the hollow section.