In-Mold Primer Coating for Porosity-Free Composite Aircraft Surfaces
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Solution Overview
Problem
Composite aircraft components made from cured fiber-reinforced resin require pre-finish steps like applying filler materials and sanding to address surface porosities, increasing production time and cost, and exposing operators to ergonomic issues.
Innovation Solution
An in-mold coating process using a water-based primer paint applied to the mold interior, followed by laying uncured prepreg plies, curing under elevated temperature and pressure, resulting in a finished surface without the need for additional finishing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional composite manufacturing processes are used, then composite aircraft components can be formed, but surface porosities are created requiring pre-finish steps
Solution Approach 1:
A primer coat is applied to the mold surface before placing the composite preform, creating a sealed surface that prevents resin infiltration and eliminates surface porosities. This preliminary action on the mold surface resolves the surface quality issue without adding post-finish steps to the composite manufacturing process.
2Manufacturing precision
If pre-finish steps are applied to correct surface defects, then smooth surfaces are achieved, but production time increases
Solution Approach 1:
The primer is applied to the mold before composite fabrication, sealing the mold surface in advance to prevent resin infiltration. This eliminates the need for post-finish steps like filling and sanding, thereby reducing production time while achieving smooth surfaces.
Solution Approach 2:
The surface finishing function is extracted from the composite manufacturing process and transferred to the mold preparation process. By applying the primer to the mold beforehand, the need for time-consuming post-finish steps on the composite part is eliminated.
3Manufacturing precision
If filler materials are applied and sanded to obtain surface quality, then paint application readiness is achieved, but operator ergonomic issues arise
Solution Approach 1:
The primer is applied to the mold surface before composite fabrication, creating a sealed surface that eliminates porosities. This prevents the need for operators to perform sanding operations on filler materials, thereby eliminating ergonomic issues while achieving paint-ready surfaces.
Solution Approach 2:
The surface preparation function is extracted from the composite part and transferred to the mold. By sealing the mold surface with primer beforehand, the need for operators to apply and sand filler materials is eliminated, improving operator safety and ergonomics.
4Manufacturing precision
If pre-finish steps are performed to achieve required surface quality, then aerodynamic surfaces are obtained, but production costs increase
Solution Approach 1:
The primer is applied to the mold surface before composite fabrication, sealing the mold to prevent resin infiltration and eliminate surface porosities. This eliminates the need for expensive post-finish steps like filler application and sanding, reducing manufacturing costs while achieving aerodynamic surfaces.
Solution Approach 2:
The surface finishing function is extracted from the composite manufacturing process and performed in advance on the mold. This eliminates the need for costly post-finish operations on the composite part, reducing overall manufacturing costs while maintaining aerodynamic surface quality.
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
The process eliminates the need for pre-finish steps, providing a smooth, aerodynamic surface directly from the mold, reducing production time and costs while ensuring operator safety.
Implementation Method 1
The primer paint material is subsequently allowed to dry (e.g., by allowing volatile material of the paint to evaporate) to form a dried film layer of the primer on the interior surface of the mold
Implementation Method 2
The resulting component preform in the mold may then be subjected to resin curing conditions (e.g., by enveloping the component preform in a vacuum bag and subjecting the component preform to elevated temperature and pressure conditions within an autoclave) sufficient to cure the one or more prepreg plies
Data Source
AI summary
Processes for forming fiber reinforced composite aircraft components, i.e., aircraft components formed of a cured fiber-reinforced resin, are provided. According to specific embodiments, a finished surface of the composite aircraft component can be achieved by providing in-mold coating of the cured fiber-reinforced resin by a dried and cured film layer of a water-based primer paint material to thereby achieve a composite aircraft component having an exterior surface that does not necessarily require further finishing.