Hollow Core Composite Sealing via Polymerizable Adhesive
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Solution Overview
Problem
Resin transfer molding processes face challenges in manufacturing composite parts with open-cell cores, as the resin tends to penetrate into the core cells, increasing resin consumption and reducing mechanical performance.
Innovation Solution
A method using an adhesive layer with resin-blocking properties, supported by glass or polymer fibers, is applied with a perpendicular pressure force, often under vacuum, to seal the core and prevent resin migration, accompanied by additional steps to ensure uniform pressure and prevent adhesive sagging, and the use of non-woven fiber plies to enhance sealing and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin transfer molding is used to manufacture composite parts with open-cell cores, then the mechanical performance for compression and low density is improved, but the resin penetrates into the core cells increasing resin consumption and weight
Solution Approach 1:
The mold is divided into separate cavities that can be independently sealed and filled, allowing selective resin application to specific regions while preventing unwanted penetration into core cells through controlled sealing mechanisms
Solution Approach 2:
A sealing layer or membrane is introduced as an intermediary between the resin and the core cells, preventing direct resin penetration while allowing the resin to reach and impregnate the fibrous reinforcement elements through controlled pathways
2Strength
If resin transfer molding is used to manufacture composite parts with open-cell cores, then the mechanical performance for compression and low density is improved, but the resin penetration weighs down the structure and decreases honeycomb structure performance
Solution Approach 1:
The mold is divided into separate cavities that can be independently sealed and filled, allowing selective resin application to specific regions while preventing unwanted penetration into core cells through controlled sealing mechanisms
Solution Approach 2:
A sealing layer or membrane is introduced as an intermediary between the resin and the core cells, preventing direct resin penetration while allowing the resin to reach and impregnate the fibrous reinforcement elements through controlled pathways
3Reliability
If multiple intermediate layers (adhesive, blocking) are used to prevent resin penetration, then resin blocking is improved, but the manufacturing process complexity increases
Solution Approach 1:
The adhesive layer and resin-blocking function are merged into a single integrated component, where the adhesive layer simultaneously provides both adhesion and resin sealing, eliminating the need for separate blocking layers
Solution Approach 2:
The adhesive layer is designed to perform multiple functions: providing adhesion between layers and simultaneously acting as a resin-blocking barrier, making it a multi-functional element that simplifies the overall structure
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 effectively seals the hollow core, reduces resin consumption, and improves mechanical performance by preventing resin infiltration and ensuring uniform pressure distribution, allowing for simpler and more efficient production of composite parts with sealed cores.
Implementation Method 1
an adhesive layer capable of also exhibiting resin-blocking properties, it is possible to seal the hollow core and to avoid filling the core with resin
Implementation Method 2
the application of a pressure force on the adhesive ply in a direction strictly perpendicular to the latter made it possible to considerably increase the sealing properties to the resin. According to a preferred embodiment, the pressure force is applied by placing the assembly to be sealed under vacuum.
Implementation Method 3
A resin is then injected into the mold and then polymerized. The molecules of this resin then begin to bind together and form a solid network.
Data Source
AI summary
The present invention relates to a process for manufacturing a part made of a composite having a hollow core (1) comprising the following steps: - applying at least one adhesive layer (6) to an open surface of the hollow core, said process being characterized in that the adhesive layer is a polymerizable blocking adhesive layer having, after polymerization, sealing properties with respect to a resin, and capable of preventing the diffusion of a resin into the hollow core; - and polymerizing the blocking adhesive layer so as to seal the hollow core.