Polymer Form for Composite Parts with Glassy Elastomeric Transition
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Solution Overview
Problem
The manufacturing of complex composite parts, such as wings with twist, taper, and camber, is hindered by the difficulty in removing molds without damaging either the part or the mold, leading to high costs and material wastage due to the need for expensive machining processes and assembly of separate pieces.
Innovation Solution
A shaped polymer form is used, which transitions between a glassy and elastomeric state, allowing it to deform and be removed from the composite part without requiring shape memory properties or inflation, and can be reused or discarded, enabling the production of one-piece composite parts with twist, taper, and camber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional molds are used for complex composite parts, then the part can be manufactured with required shape, but the mold cannot be removed from the finished part without damage
Solution Approach 1:
The patent applies parameter changes by transitioning the polymer form between glassy and elastomeric states through temperature control. The form is heated above its glass transition temperature to become elastomeric for easy removal, then cooled to return to glassy state for reuse. This resolves the contradiction by enabling mold removal while maintaining complex part shapes.
Solution Approach 2:
The patent makes the mold dynamic by allowing it to change its physical state between rigid (glassy) and flexible (elastomeric). This dynamic state change enables the mold to adapt to removal requirements while maintaining structural integrity during manufacturing, solving the removal difficulty for complex parts.
2Manufacturing precision
If expensive machining processes are used to create molds, then the mold can be made with required precision, but the manufacturing cost increases
Solution Approach 1:
The patent uses parameter changes (temperature-induced phase transition) to enable a simple polymer form to achieve the functionality of expensive precision molds. The polymer form maintains required precision through its glassy state rigidity while being manufactured via low-cost molding processes, eliminating the need for expensive machining.
Solution Approach 2:
The patent employs disposable or reusable polymer forms that can be manufactured cheaply through molding processes. These forms replace expensive, precision-machined traditional molds, significantly reducing manufacturing costs while maintaining adequate precision for complex part fabrication.
3Shape
If separate pieces are assembled to create complex parts, then the part can be manufactured, but the assembly process increases complexity and cost
Solution Approach 1:
The patent applies preliminary action by forming the complete complex geometry in a single molding operation using a polymer form. The form is manufactured with the desired complex shape beforehand, allowing the composite part to be cured as a one-piece structure without subsequent assembly operations, thereby reducing complexity.
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 method reduces manufacturing costs and capital investment by allowing for the efficient production of complex composite parts without the need for expensive mold removal processes, enabling the creation of lightweight and strong composite wings for air vehicles.
Implementation Method 1
heating to a temperature above its glass transition temperature to transform it from a rigid substance to an elastic, flexible and soft substance
Data Source
AI summary
A polymer is formed into the shape of a one-piece composite part and then solidified by curing, setting, hardening or otherwise solidifying the polymer to form a shaped polymer form having a shape that does not draw. Composite material is laid up on the form and solidified to from the composite part. The rigidity required of the form to lay up the composite part can be provided by operating in the polymer form's glassy state, forming the shaped polymer form with a hollow core and placing a rigid insert designed to draw inside the hollow core with the polymer form in its elastomeric state or through a combination of both. In its elastomeric state the form becomes pliable (without relaxing to a different memorized shape) and can be drawn out of the one-piece composite part. Because the shape of the form does not draw, the form deforms as it is drawn. If used, the rigid insert is drawn out prior to removing the shaped polymer form. Upon removal, the polymer form in its elastomeric state returns to its original shape. The form may be used once and thrown away or reused to form multiple composite parts of the same shape.