Injection Structure Degassing for Fiber-Composite Components

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Solution Overview

Problem

In the manufacture of fiber-composite components using resin injection methods, pores often form due to gas bubbles and volatile constituents in the matrix material, leading to reduced quality, incomplete degassing near gate areas, and increased material costs and reactions with auxiliary materials.

Innovation Solution

An injection structure with a gate device, a distribution fabric, and a matrix-material-impermeable barrier layer that allows gas permeability, positioned between the distribution fabric and the fiber-composite semifinished product, facilitating effective degassing of the matrix material before infiltration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If matrix material is introduced through gate devices directly adjacent to the semifinished product, then injection speed and productivity are improved, but pore formation increases due to incomplete degassing

Engineering Contradiction:

Improveinjection speedVSAvoidpore formation

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by implementing a degassing chamber that processes the matrix material before it reaches the semifinished product. The matrix material is forced through a membrane in the degassing chamber, allowing gas bubbles to be removed in advance. This preliminary degassing step ensures that the matrix material is free of volatile constituents before injection, preventing pore formation while maintaining high injection speeds.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If a two-chamber system with gas-permeable membrane is used for degassing, then degassing effectiveness is improved, but device complexity and material expenditure increase

Engineering Contradiction:

Improvedegassing effectivenessVSAvoidchamber structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts the essential degassing function from the complex two-chamber system and implements it through a simplified single-chamber design with a gas-permeable membrane. The membrane selectively allows gas to pass through while blocking the matrix material, achieving effective degassing without requiring separate evacuation chambers. This extraction of the core function reduces structural complexity while maintaining degassing effectiveness.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If matrix material is heated for degassing in an evacuated space, then degassing effectiveness is improved, but energy consumption and material aging increase

Engineering Contradiction:

Improvedegassing effectivenessVSAvoidheating energy

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent replaces the thermal heating method with a mechanical pressure-driven system. Instead of heating the matrix material to facilitate degassing, the invention uses a gas-permeable membrane that allows gas to escape through pressure differential and vacuum suction. This mechanical substitution eliminates the need for heating, reducing energy consumption and preventing thermal aging of the matrix material while maintaining effective degassing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If the matrix material layer is made thinner for film degassing, then degassing effectiveness is improved, but the risk of reactions with auxiliary materials and absorption of volatile constituents increases

Engineering Contradiction:

Improvedegassing effectivenessVSAvoidreactions with auxiliary materials

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a gas-permeable membrane as an intermediary between the matrix material and the evacuated chamber. This membrane acts as a selective barrier that allows gas molecules to pass through while blocking the matrix material from contacting the evacuation system and auxiliary materials. The membrane mediates the degassing process, enabling effective gas removal without exposing the matrix material to harmful reactions or re-absorption risks.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces the probability of pore formation, enhances the quality and robustness of fiber-composite components, and minimizes material expenditure by ensuring thorough degassing and reducing reactions with auxiliary materials.

Implementation Method 1

the barrier layer can be gas-permeable and matrix-material-impermeable

Methodology Applied

Scientific EffectGas permeability: Permeation

Implementation Method 2

Air is removed from the second space by suction

Methodology Applied

Scientific EffectVacuum suction: Suction

Data Source

PatentUS7931458B2Method and devices for producing fiber-reinforced components

Publication Date: 2011.04.26 AIRBUS DEFENCE & SPACE GMBH

AI summary

Injection structure with a fiber-composite semifinished product for manufacturing a fiber-composite component, having a gate device for feeding matrix material, a distribution fabric, and a barrier layer that is impermeable to the matrix material, wherein the distribution fabric is arranged between the gate device and the fiber-composite semifinished product, and the barrier layer is arranged between the distribution fabric and the fiber-composite semifinished product, as well as device for manufacturing a fiber-composite component by this injection structure.