Low Temperature Resin Curing for Standard Foam Core Stability
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Solution Overview
Problem
High-pressure resin transfer molding (HP-RTM) processes face limitations in using standard foam cores due to high pressure and temperature requirements, leading to either costly specialty foams or slow cure resins, which result in either expensive or time-consuming production.
Innovation Solution
A process using low viscosity resin with fast curing times at low mold temperatures (up to 100°C) and moderate in-mold pressures (0.2 to 2.5 MPa) to combine fast cure resins with standard foam cores, allowing for lightweight, mechanically stable composite materials production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-pressure resin transfer molding (HP-RTM) is used with high in-mold pressure and high mold temperatures to achieve fast curing time, then productivity is improved, but the core material collapses leading to manufacturing defects
Solution Approach 1:
The patent changes the chemical parameters of the resin system by using a two-component polyurethane composition with specific molecular weight ranges and functionality ratios. This chemical modification enables the resin to cure rapidly at low temperatures (below 100°C) and moderate pressures (0.2 to 2.5 MPa), resolving the contradiction between fast curing and core material integrity by eliminating the need for high-temperature/high-pressure processing
2Ease of manufacture
If standard foam cores are used with high-pressure resin transfer molding, then ease of manufacture is improved, but the foam cores collapse under high pressure and temperature
Solution Approach 1:
The patent modifies the processing parameters by using a specialized two-component polyurethane resin system that cures at low temperatures and moderate pressures. This enables the use of standard, inexpensive foam cores without collapse, maintaining both ease of manufacture with common materials and reliability of part quality
Solution Approach 2:
The patent employs a composite resin system consisting of polyol and polyisocyanate components that react to form a polyurethane matrix. This composite material approach creates a resin with tailored properties that can cure rapidly under gentle processing conditions, compatible with standard foam cores
3Productivity
If fast curing resin is used with standard foam cores at low pressure, then productivity is improved, but the resin cannot achieve proper cure without high pressure and temperature
Solution Approach 1:
The patent changes the chemical composition parameters of the resin by using a two-component polyurethane system with specific molecular weights and functionality ratios. This chemical formulation enables complete and rapid curing at low temperatures and moderate pressures, achieving both fast cycle times and proper cure completeness without requiring high-pressure processing
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
Enables the use of standard foam cores with low pressure stability and fast cycle times, achieving high in-mold pressures and preventing core material collapse, suitable for lightweight sandwich-structured composite materials with improved mechanical stability and reduced production costs.
Implementation Method 1
curing of the matrix material is affected at a temperature of no more than 100° C.
Data Source
AI summary
A process for the production of composite materials at low temperatures, as well as a composite material obtained by the process and articles of manufacture comprising the composite material are provided.