Nanostructure Array Alignment in Composite Infusion
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Solution Overview
Problem
Incorporating aligned nanostructures into fiber reinforced composites using infusion-based methods, such as RTM and VARTM, is challenging due to difficulties in maintaining their alignment and adhesion to dry fiber layers, leading to disrupted alignment and non-uniform distribution during the resin infusion process.
Innovation Solution
The use of a hybrid nanocomposite product with a nanostructure array and a resin matrix, where the nanostructures are aligned and maintained within a resin film, which is then infused into dry fiber layers, using methods like resin-transfer molding, vacuum-assisted resin transfer molding, or resin film infusion, to preserve alignment and adhesion during the composite formation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aligned nanostructures are incorporated into fiber reinforced composites using infusion-based methods, then the mechanical, thermal, and electrical properties of the composite are enhanced, but the alignment and positioning of nanostructures are disrupted during the resin infusion process
Solution Approach 1:
The patent applies preliminary action by pre-aligning the nanostructures on a carrier substrate before the resin infusion process begins. The nanostructures are arranged in their desired aligned configuration and positioned on the carrier, which then serves as a pre-prepared unit that maintains this alignment throughout subsequent processing steps, including resin infusion and curing.
Solution Approach 2:
The patent uses a carrier substrate as an intermediary element between the nanostructures and the final composite structure. This carrier serves as a temporary support that holds the nanostructures in their aligned positions during handling and processing, and is subsequently removed after the resin has cured, leaving the nanostructures properly positioned in the final composite.
2Strength
If aligned nanostructures are incorporated into fiber reinforced composites, then the material properties are enhanced, but the adhesion of nanostructures to dry fiber layers is difficult to achieve
Solution Approach 1:
The carrier substrate acts as an intermediary that facilitates adhesion during the manufacturing process. The nanostructures adhere to the carrier substrate, which is then placed against the dry fiber layers. During resin infusion, the resin flows between the carrier and the fiber layers, creating bonding interfaces. After curing, the carrier is removed, leaving the nanostructures properly adhered to the composite structure through the cured resin.
Solution Approach 2:
The patent performs preliminary adhesion preparation by having the nanostructures pre-aligned and positioned on the carrier substrate before the actual composite assembly. This pre-positioning ensures that when the carrier is placed against the dry fiber layers and resin is infused, the nanostructures are already in their correct positions and will adhere properly to the surrounding resin and fiber structure.
3Productivity
If nanostructures are incorporated using infusion-based methods, then the composite can be formed, but the distribution of nanostructures becomes non-uniform
Solution Approach 1:
The patent applies preliminary action by pre-distributing the nanostructures uniformly across the carrier substrate surface before the infusion process. This pre-distribution ensures that when the resin flows through the composite during infusion, the nanostructures are already in their final positions and will maintain uniform distribution throughout the cured composite, eliminating the non-uniform distribution problem associated with traditional infusion methods.
Solution Approach 2:
The carrier substrate serves as an intermediary that enables uniform distribution of nanostructures. By providing a flat, stable surface on which nanostructures can be uniformly arranged before processing, the carrier ensures that the nanostructures maintain their uniform distribution pattern throughout the resin infusion and curing process, and in the final composite structure.
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 approach effectively maintains the alignment and positioning of nanostructures within the composite, enhancing mechanical, thermal, and electrical properties, while ensuring uniform distribution and integration with the resin matrix, thereby improving the overall performance of the composite material.
Implementation Method 1
Methods are presented for infusing composites via resin-transfer molding (RTM), vacuum-assisted resin transfer molding (VARTM), resin film infusion (RFI), or injection molding
Implementation Method 2
Methods are presented for infusing composites via resin-transfer molding (RTM), vacuum-assisted resin transfer molding (VARTM), resin film infusion (RFI), or injection molding
Implementation Method 3
a resin matrix film that substantially maintains alignment and position of the nanostructure array during the infusion process
Implementation Method 4
Transfer of resin into dry fiber forms may be provided when the product acts as a resin transfer medium
Data Source
AI summary
An article includes a hybrid nanocomposite product, which includes a nanostructure array and a resin matrix contained among and/or around the nanostructure array. The array/matrix is placed in between layers of dry or resin-infused fiber composite to permit formation of a composite structure. The nanostructure array and/or the resin matrix may be disposed in an abutting relationship with other layers of a composite. The array/matrix can provide reinforcement of the composite in the z-direction. Transfer of resin into dry fiber forms may be provided when the array/matrix acts as a resin transfer medium. Nanostructure arrays with a resin matrix can be prepared to form a resin film product. Methods are presented for infusing composites via resin-transfer molding (RTM), vacuum-assisted resin transfer molding (VARTM), resin film infusion (RFI), or injection molding wherein a resin matrix film substantially maintains alignment and position of the nanostructure array during the infusion process.