Preform Patch with Suction Space for Composite Reinforcement
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Solution Overview
Problem
Existing methods for reinforcing fiber composite components, such as those used in wind turbines, face challenges in reliably distributing matrix material during the infusion process, leading to potential bubbles and incomplete reinforcement.
Innovation Solution
A preform patch with a tear-off fabric, flow medium, and vacuum film layers, where the flow medium is arranged in a distributor space delimited by the vacuum film, and a gas-permeable but matrix-impermeable membrane with a spacer fabric creates a sealed suction space, allowing for controlled matrix material distribution and saturation of the fiber ply without gas separation, enabling efficient reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a preform patch is used for reinforcing fiber composite components, then the load bearing capacity and structural integrity are improved, but the complexity of the reinforcement structure increases
Solution Approach 1:
The preform patch is divided into multiple functional layers including tear-off fabric, flow medium, vacuum film, membrane, and spacer fabric. Each layer performs a specific function: tear-off fabric for easy removal, flow medium for matrix distribution, vacuum film for sealing, membrane for gas permeability, and spacer fabric for creating suction space. This segmentation allows complex reinforcement functionality to be achieved through simple, dedicated layers rather than a single complex structure.
Solution Approach 2:
The patent introduces intermediary components to facilitate the reinforcement process. The flow medium acts as an intermediary to distribute matrix material evenly. The vacuum film and membrane create a controlled vacuum environment that facilitates matrix infusion. The spacer fabric creates a suction space that draws matrix material through the patch. These intermediaries simplify the overall process by handling specific functions that would otherwise require complex integrated structures.
2Reliability
If matrix material is introduced into the preform patch for saturation, then the reinforcement effectiveness is improved, but the risk of bubble formation and incomplete distribution increases
Solution Approach 1:
The patent employs vacuum technology to create a suction force that draws matrix material through the preform patch. The vacuum film and membrane enclose a suction space where negative pressure is maintained. This pneumatic approach ensures complete matrix distribution by actively pulling the material through all layers and into the fiber composite, eliminating trapped air bubbles and ensuring 100% saturation without relying on passive diffusion or gravity alone.
Solution Approach 2:
The flow medium and spacer fabric utilize porous structures to facilitate matrix material passage. The porous nature of these materials allows the matrix to permeate through evenly while the vacuum pressure ensures complete saturation. The porous structure prevents bubble entrapment by allowing air to escape through the same pathways the matrix material uses, ensuring clean, bubble-free reinforcement.
3Manufacturing precision
If a complex multi-layer preform patch is used for controlled matrix distribution, then the distribution reliability is improved, but the ease of manufacture decreases
Solution Approach 1:
The preform patch is manufactured as a complete multi-layer assembly before application to the fiber composite component. All layers are pre-positioned and pre-sealed during manufacturing, including the tear-off fabric, flow medium, vacuum film, membrane, and spacer fabric. This preliminary assembly ensures precise layer alignment and sealing without requiring complex on-site assembly procedures, actually simplifying manufacturing despite the multiple layers involved.
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 preform patch ensures reliable distribution and saturation of matrix material within the fiber composite component, reducing the risk of bubbles and incomplete reinforcement, while allowing for easy removal and maintaining the component's structural integrity.
Implementation Method 1
a gas permeable but matrix material impermeable membrane and a ply of a spacer fabric, wherein the space filled by the spacer fabric forms a suction space, which is sealed in a matrix material tight manner with respect to the distributor space
Implementation Method 2
a gas permeable but matrix material impermeable membrane
Data Source
AI summary
The use of a preform patch (2) having, on its side facing the surface of the fiber composite component (8), at least one ply of a tear-off fabric (10) as a first ply, above that at least one ply of a flow aid (12), and above that at least one ply of a vacuum film (14), wherein the at least one ply of the flow aid (12) is disposed in a distributor space (16) for distribution of the matrix material (6) over the fiber layer (4a) of a fiber material bounded on the outside by the vacuum film (14), and the preform patch (2) has a gas permeable but matrix material impermeable membrane (18) and a ply of a spacer fabric (20), wherein the space filled by the spacer fabric (20) forms a suction space (22) sealed in a matrix material tight manner with respect to the distributor space (16).