Microporous Membrane Resin Retention Composite Molding
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Solution Overview
Problem
Existing multilayer complexes for vacuum molding of composite materials, such as those described in FR 2 868 008 A1, consume excessive resin due to their perforated membranes, affecting mechanical performance and increasing costs, as they are not fully impermeable to resin.
Innovation Solution
A multilayer complex comprising a microporous membrane with smaller pores, made from materials like polyethylene or polytetrafluoroethylene, which is gas-permeable but nearly impermeable to resin, reducing resin usage by retaining most of the resin during the molding process while allowing gas evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a perforated membrane is used for gas evacuation, then gas permeability is improved, but resin retention deteriorates
Solution Approach 1:
The patent employs a microporous membrane with specifically controlled pore sizes that allow gas molecules to pass through while blocking larger resin molecules. This porous structure with selective permeability enables simultaneous gas evacuation and resin retention, resolving the contradiction between gas permeability and resin retention.
Solution Approach 2:
The membrane exhibits different permeability properties for different substances (gas versus resin) due to its microporous structure. The local pore structure allows gas to pass while retaining resin, creating selective local quality that addresses the contradiction between gas evacuation and resin retention.
2Speed
If a perforated membrane is used to allow gas passage, then gas permeability is improved, but mechanical performance deteriorates
Solution Approach 1:
The microporous membrane provides sufficient structural integrity to maintain mechanical performance while its controlled pore structure enables gas evacuation. The porous design allows gas passage without creating large holes that would compromise the mechanical strength of the composite material.
3Loss of substance
If a non-perforated membrane is used to retain resin, then resin retention is improved, but gas evacuation deteriorates
Solution Approach 1:
The microporous membrane combines resin retention capability with gas evacuation functionality through its controlled pore structure. The pores are small enough to retain resin molecules but large enough and sufficiently numerous to allow efficient gas evacuation, eliminating the need for mechanical perforation.
4Loss of substance
If excessive resin is used to compensate for membrane permeability, then resin retention is improved, but manufacturing cost deteriorates
Solution Approach 1:
The microporous membrane's selective permeability reduces resin loss during the molding process, allowing for more efficient resin usage. This eliminates the need to add excessive resin as a compensatory measure, thereby reducing material costs and improving manufacturing economy.
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 microporous membrane effectively reduces resin consumption, maintaining mechanical performance and lowering production costs by minimizing resin loss, while allowing efficient gas evacuation and resin distribution within the composite material.
Implementation Method 1
a microporous membrane (3) made from materials like polyethylene or polytetrafluoroethylene, which is gas-permeable but nearly impermeable to resin
Implementation Method 2
The microporous character of the membrane of the multilayer complex according to the present invention comes from its manufacture
Data Source
Figure 1
AI summary
The invention relates to a multilayer complex for vacuum-molding a composite part containing a fibrous reinforcement and a polymer resin, including a peel-ply fabric (2) combined with a microporous membrane (3) that is at least pervious to gas, and to a vacuum-molding method using such a complex.