Magnetic Gap Closure for Composite Preform Alignment

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Solution Overview

Problem

Manufacturing polymeric composite components with complex geometries faces challenges in holding edges together during polymer injection, leading to resin-rich areas that are weak and requiring manual, time-consuming processes.

Innovation Solution

Utilizing a fiber preform with ferromagnetic and magnetizable components to close gaps using magnetic fields, allowing for automated alignment and injection of a polymer precursor to form a strong, three-dimensional composite component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual processes are used to hold edges together during polymer injection, then alignment can be achieved, but the process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvealignment precisionVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical holding processes with a magnetic field-based system. Ferromagnetic materials embedded in the fiber preform interact with magnetic fields generated by magnets in the mold to automatically hold edges together during polymer injection, eliminating the need for manual intervention while maintaining precise alignment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If gaps between fiber preform edges are not properly closed, then the manufacturing process is simpler, but resin-rich areas form that are weak and reduce component strength

Engineering Contradiction:

Improveprocess simplicityVSAvoidcomponent strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent uses magnetic fields to automatically close gaps between fiber preform edges during the injection process. Ferromagnetic materials in the preform are attracted to magnets in the mold, pulling the edges together to eliminate gaps and prevent resin-rich areas, thereby maintaining component strength without complicating the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Extent of automation

If ferromagnetic materials and magnetic components are added to the fiber preform, then automated alignment and gap closing is achieved, but the device complexity increases

Engineering Contradiction:

Improveautomation levelVSAvoidpreform structure complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent applies ferromagnetic materials locally at specific locations within the fiber preform where gap closing and alignment are needed, rather than throughout the entire preform. This targeted approach enables automated control while minimizing the addition of complex components and maintaining overall system simplicity.

Inventive Principle:

Principle #3Local 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 method ensures a composite component with improved strength and reduced resin-rich areas, enabling efficient production of complex shapes with high precision and reduced manual labor.

Implementation Method 1

closing the gap by generating a magnetic field from the first magnetic or magnetizable component

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component

Methodology Applied

Scientific EffectMagnetism: Magnetism

Implementation Method 3

the first magnetic or magnetizable component includes an electromagnetic circuit. The electromagnetic circuit includes an electrically-conductive coil at least partially defining an interior region and a core disposed at least partially within the interior region. The core includes a second ferromagnetic material. The closing includes supplying current to an inductor to generate a magnetic field from the electromagnetic circuit

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 4

injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS11642819B2Composite components and methods of manufacturing composite components using magnetic forces at fiber preform seams

Publication Date: 2023.05.09 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method of manufacturing a composite component according to various aspects of the present disclosure includes disposing a fiber preform in a mold. The fiber preform includes a first portion having a first edge and a second portion having a second edge. The first edge and the second edge cooperate to at least partially define a gap. One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component. The method further includes closing the gap by generating a magnetic field from the first magnetic or magnetizable component. The method further includes injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer. The composite component includes the fiber preform and the polymer.