Intermediate Fibrous Layer for Resin Flow Control in RTM
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Resin injection methods in fiber composite production lead to uneven matrix distribution due to cavities and air enclosures, resulting in variable precision and high production costs, with temperature control methods being inefficient and costly.
Innovation Solution
Incorporating a randomly oriented intermediate fibrous layer between the fibrous material blank and the mold surface to regulate resin flow speed and ensure homogeneous resin distribution, achieved through roughening or flocking processes, which also eliminates the need for precise temperature control and pressure adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resin is injected into the mold cavity, then the fibrous material blank is impregnated with resin, but cavities and air enclosures remain between the fibrous material and mold surface, causing uneven resin distribution
Solution Approach 1:
A layer of randomly oriented fibers is introduced as an intermediary material between the fibrous material blank and the mold surface. This intermediate layer fills the cavities and prevents air enclosures by providing a pathway for resin to reach the mold surface uniformly, thereby eliminating the harmful effect of cavities while maintaining good resin distribution.
Solution Approach 2:
The layer of randomly oriented fibers acts as a porous material that allows resin to flow through it while maintaining contact with the mold surface. The porous structure enables the resin to penetrate and fill cavities effectively, ensuring uniform resin distribution without creating air enclosures.
2Productivity
If resin flows quickly through cavities, then injection time is reduced, but resin reaches ventilation aperture too fast and covers it, causing air enclosures
Solution Approach 1:
The layer of randomly oriented fibers serves as a mediator that regulates resin flow speed. It slows down the resin flow from the injection point, preventing the resin from reaching the ventilation aperture too quickly, thereby avoiding air enclosures while maintaining efficient injection.
Solution Approach 2:
The introduction of the fiber layer changes the flow parameters of the resin by increasing flow resistance in a controlled manner. This parameter change slows down the resin flow velocity, allowing the resin to fill the mold cavity uniformly without covering the ventilation aperture prematurely.
3Manufacturing precision
If temperature control is used to control resin flow, then resin flow speed can be regulated, but production costs and tool costs increase significantly
Solution Approach 1:
Instead of using expensive and complex temperature control systems, a simple and inexpensive layer of randomly oriented fibers is used to control resin flow. This disposable-like material provides effective flow regulation without the high costs associated with thermal control equipment and energy consumption.
Solution Approach 2:
The patent replaces the mechanical/thermal control system (temperature control) with a passive structural solution (fiber layer). The resin flow control is achieved through the physical structure of the fiber layer rather than active thermal management, significantly reducing production and tool 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 enhances production precision by ensuring uniform resin flow and penetration into the fibrous material, reducing costs and simplifying the process while maintaining high-quality fiber composite part production.
Implementation Method 1
the flowing speed of the resin is reduced due to said intermediate fibrous layer
Data Source
AI summary
The present invention relates to a method for the production of a fiber composite part, with a fibrous blank (6) being inserted into a mold (1) and the mold (1) being closed, and a matrix being injected into the closed mold (1), which is characterized in that at least sectionally an intermediate fibrous layer (15) is arranged locally fixed between the outer shell surface (7) of the fibrous material blank (6) and the inner shell surface (5) of the mold (1), so that the flow rate of the resin is reduced due to the randomly arranged fibers (15).