Prepreg Gas Venting Network for Void Reduction
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Solution Overview
Problem
Prepregs face challenges in maintaining stability during storage at ambient temperatures and in reducing void formation in composite parts due to gas trapped during curing, which affects the strength and quality of the final laminate.
Innovation Solution
Incorporating a multi-dimensional gas venting network and penetrable barriers within the prepreg structure to allow efficient gas escape during curing, while maintaining a non-flow state during storage, ensuring effective gas removal and reducing void formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If penetrable barriers are added to enhance long-term storability at ambient temperature, then storage stability is improved, but device complexity increases
Solution Approach 1:
Penetrable barriers are pre-positioned between matrix precursor elements during prepreg manufacturing to prevent premature flow and maintain stability during storage. These barriers only become permeable when exposed to curing temperature, allowing gas escape at the appropriate time. This preliminary placement resolves the contradiction by ensuring storage stability is improved without requiring complex active control mechanisms.
Solution Approach 2:
The penetrable barriers exhibit temperature-dependent permeability properties, transitioning from impermeable at storage temperatures to permeable at curing temperatures. This parameter change allows the same structure to serve dual functions: maintaining stability during storage and enabling gas venting during curing, thereby improving storage stability without proportionally increasing device complexity.
2Manufacturing precision
If a multi-dimensional gas venting network is incorporated to reduce void formation, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The gas venting network extends in multiple dimensions (x, y, and z directions) through the prepreg structure, creating comprehensive gas escape pathways. This multi-dimensional approach improves void formation control by capturing gas bubbles from all directions during curing, while the integrated design ensures the complexity increase is justified by the significant improvement in laminate quality.
Solution Approach 2:
The gas venting network is segmented into multiple pathways distributed throughout the prepreg structure, with individual channels in different orientations. This segmentation allows gas to escape through multiple routes rather than relying on a single complex venting mechanism, improving manufacturing precision while managing device complexity through distributed simplicity.
3Productivity
If matrix precursor elements are arranged in specific configurations to form gas venting networks, then gas removal efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The matrix precursor elements serve dual functions: providing the structural matrix for the composite material and forming the gas venting network through their specific configuration. This multi-functionality improves gas removal efficiency without requiring separate dedicated venting components, thereby reducing manufacturing complexity while enhancing productivity.
Solution Approach 2:
The gas venting network is merged with the matrix precursor element structure itself, rather than being a separate component. The specific configurations of matrix precursor elements create interconnected void spaces and pathways that facilitate gas escape. This merging eliminates the need for additional manufacturing steps to create separate venting structures, improving gas removal efficiency while maintaining 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
The solution enables long-term storage of prepregs at ambient temperatures and reduces void formation in the cured laminate, enhancing the strength and quality of composite parts.
Implementation Method 1
Each of the matrix precursor elements is surrounded by a penetrable barrier that forms a barrier zone that prevents the matrix precursor elements from flowing into the barrier zone when the prepreg is stored at ambient temperature
Implementation Method 2
The penetrable barrier allows the matrix precursor elements to flow into the barrier zone when the prepreg is heated to a curing temperature
Implementation Method 3
Gas generated during the curing process can become trapped within the laminate where it forms pores or voids
Implementation Method 4
prepreg are provided that include gas venting networks that allow multi-dimensional escape of gas from the prepreg during the curing process
Data Source
AI summary
Composite prepreg including a gas venting network that allows multi-dimensional escape of gas from the prepreg during the curing process. Penetrable barriers are also provided between the matrix precursor elements to promote long-term storability of the prepreg at ambient temperatures. All or a portion of the gas venting network may be integrated with the penetrable barriers.