Inflatable Hose Core for Adaptive Composite Tooling
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Solution Overview
Problem
Current methods for producing T-shaped reinforcing elements using rigid tool cavities in fiber-reinforced composite materials face challenges in adapting tool geometry to component dimensions, leading to quality issues like porosity, fiber misorientation, and unnecessary material removal through costly and laborious processes.
Innovation Solution
A method involving the use of inflatable, folded hose cores within rigid form tools to exert pressure on preformed reinforcing fibers, allowing for adaptive filling and consolidation without excessive pressure, enabling near-net-shape production and reducing material waste, with the option to add protective or indicator materials for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid tool cavities are used for producing T-shaped reinforcing elements, then high component quality is achieved, but tool modification is required to adapt to component geometry changes
Solution Approach 1:
The tool cavity is segmented into rigid form tool walls and a flexible hose core filler. The rigid walls provide structural support and quality, while the flexible hose core adapts to geometry changes, dividing the tool into functional segments that solve both quality and adaptability requirements
Solution Approach 2:
The hose core transitions from a static rigid cavity to a dynamic flexible element that can be inflated and deflated. This dynamic adjustment allows the tool to adapt to different component geometries while maintaining the quality benefits of rigid tooling
2Manufacturing precision
If tool cavities are modified to reduce cured dimensions, then quality problems are avoided, but additional process steps and material removal are required
Solution Approach 1:
The hose core is pre-positioned within the rigid form tool before composite layup. By preparing the flexible filler in advance, the tool is ready to adapt to exact geometry requirements from the start, avoiding post-curing adjustments and material removal steps
3Adaptability or versatility
If filler pieces made of rubber-like material are used, then adaptability is improved, but production costs and handling costs increase
Solution Approach 1:
The hose core serves multiple functions: it provides geometry adaptation, maintains tool cavity pressure, and supports the composite structure during curing. This multi-functionality eliminates the need for separate filler pieces and reduces overall production costs
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 provides cost-effective adaptation of tool cavities, improves surface quality, reduces material waste, and allows for additional functional layers like corrosion protection, while maintaining high component quality without the need for extensive tool modification or material removal.
Implementation Method 1
inflating the hose core so as to exert pressure on that end side of the preformed reinforcing fibers that is oriented away from the component that is to be reinforced
Data Source
AI summary
A method for the production of stiffened components made of fiber-reinforced composite material using two rigid form tools which are suitable for covering the longer end sides of T-shaped preformed reinforcing fibers, using a folded hose core and inflation of the hose core so as to exert pressure on the end side of the preformed reinforcing fibers.