Selective Curing Resin Dam for Composite Ledge Squeeze-out
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Solution Overview
Problem
The challenge in manufacturing composite laminates with ledges is the occurrence of resin squeeze-out (resin bleed) during the curing process, which requires additional machining to remove displaced resin and can interfere with the assembly and performance of the structure, and existing solutions like low-flow prepregs have trade-offs in performance and cost.
Innovation Solution
The method involves selectively curing a portion of the prepreg layer adjacent to ledges, creating a resin dam that prevents resin from flowing onto the ledges during curing, thereby reducing resin bleed and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If low-flow prepregs are used to reduce resin squeeze-out, then resin bleed is reduced, but performance and cost are compromised
Solution Approach 1:
The curing process is segmented into two distinct stages: selective curing of portions adjacent to ledges, and subsequent curing of the remainder. This segmentation allows the first sub-laminate and second sub-laminate to be joined with controlled resin flow, preventing squeeze-out at ledges while maintaining overall structural integrity and performance.
Solution Approach 2:
The first sub-laminate and second sub-laminate are joined together before the final curing step. This preliminary assembly allows the resin to be contained between the laminates during initial curing, preventing squeeze-out at ledges while the structure maintains its structural properties through the joining action.
2Object-generated harmful factors
If low-flow prepregs are used to reduce resin squeeze-out, then resin bleed is reduced, but manufacturing cost increases
Solution Approach 1:
The curing process is divided into selective curing and remainder curing steps, allowing standard prepreg materials to be used instead of expensive low-flow variants. This segmented approach achieves resin control through process design rather than material cost.
Solution Approach 2:
The curing parameters are changed by applying heat selectively to different portions of the prepreg layer at different times. By controlling the temperature distribution and curing sequence, resin flow is managed without requiring specialized expensive materials.
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 prevents resin contamination on ledges with minimal impact on structural properties, offering cost savings and performance improvements by reducing the need for post-fabrication machining and maintaining the functionality of critical components.
Implementation Method 1
selectively curing a portion of the prepreg layer adjacent to the ledge
Data Source
AI summary
Described herein are techniques for reducing resin squeeze-out including a method comprising receiving a first component and a second component, where the first component is configured to be joined to the second component at an overlap area using an adhesive layer to form a structure having a ledge. The method further comprises applying the adhesive layer to the overlap area on the first component. The method further comprises selectively curing a portion of the adhesive layer adjacent to the ledge. The method further comprises forming the structure by combining the first component, the second component, and the adhesive layer and curing a remainder of the adhesive layer.