Multilayer Flexible Planar Material for Composite Manufacturing
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Solution Overview
Problem
The existing vacuum-assisted process for producing fibre-reinforced plastic components is time-consuming and prone to errors due to the precise and sequential placement of individual layers in the multilayer, flexible planar material, which can affect process safety and lead to non-uniform matrix material accumulation.
Innovation Solution
A multifunctional laminate is created by securely connecting the diaphragm, textile layer, and spacer layer, allowing for simultaneous performance of gas permeability and pressure-mediated resin infiltration, eliminating the need for individual layer placement and ensuring precise arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual layers (diaphragm, spacer layer, gas-impermeable sheet) are placed sequentially and precisely, then the VAP process can be performed, but the setup time increases and process safety decreases
Solution Approach 1:
The patent combines the diaphragm, spacer layer, and gas-impermeable sheet into a single integrated planar material structure. This merging eliminates the need for sequential placement of individual layers, thereby reducing setup time and minimizing the risk of misalignment or improper assembly that compromises process safety.
Solution Approach 2:
The integrated planar material performs multiple functions simultaneously: the diaphragm provides gas permeability while blocking matrix material, the spacer layer maintains separation between layers, and the gas-impermeable sheet seals the vacuum space. This multi-functionality in a single component streamlines the setup process and enhances reliability.
2Manufacturing precision
If individual layers are placed sequentially, then the VAP process can be performed, but the placement precision and uniformity of matrix material accumulation are compromised
Solution Approach 1:
By merging the diaphragm, spacer layer, and gas-impermeable sheet into a single integrated planar material, the patent eliminates the complexity of arranging multiple separate layers. This integration ensures consistent spacing and alignment throughout the matrix supply space, guaranteeing uniform matrix material accumulation and improving manufacturing precision.
3Ease of manufacture
If separate layers are used for diaphragm, spacer layer, and gas-impermeable sheet, then the VAP process can be performed, but production costs increase
Solution Approach 1:
The patent merges three separate components (diaphragm, spacer layer, gas-impermeable sheet) into a single integrated planar material. This reduces the total number of components that need to be manufactured, stored, and assembled, thereby lowering production costs and simplifying the ease of manufacture.
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 significantly reduces setup time, enhances process safety and precision, and lowers production and material costs by integrating the layers into a single, easily applied unit.
Implementation Method 1
the gas-permeable, but matrix-impermeable diaphragm
Implementation Method 2
holds the sheet at a distance from the diaphragm when a reduced pressure is generated between the diaphragm and sheet
Implementation Method 3
the region between the sheet and the diaphragm is evacuated and a reduced pressure is as a result built up, the pressure is accordingly reduced through the diaphragm even in the interior matrix supply space, as a result of which liquid resin is drawn out of an external resin container into the matrix supply space
Implementation Method 4
the diaphragm, a textile layer, which is laminated onto the diaphragm
Data Source
AI summary
A multilayer, flexible planar material for delimiting a matrix supply chamber during the production of fiber-reinforced plastic components made of fiber composite semifinished products includes a multifunction laminate, which has a diaphragm, a textile layer, which is laminated on the diaphragm, and a spacer layer, which is disposed on the textile layer.