Resin Transfer Moulding Flow Control for Fibre Pack Compaction
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Solution Overview
Problem
Existing vacuum-assisted resin transfer moulding (VARTM) techniques struggle to maintain precise control over resin flow rates to ensure the fibre pack remains compacted and the negative pressure within the mould enclosure is maintained, especially for large articles like boat hulls, leading to potential loss of shape control and compaction.
Innovation Solution
A system with a controller that uses resin spread detectors, pressure sensors, and a manifold with variable valves to regulate resin flow based on resin spread parameters, pressure differentials, and flow control apparatus to maintain negative pressure within the mould enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resin pump output is increased to maintain flow rate, then resin introduction speed increases, but negative pressure within the enclosure is lost and fibre pack compaction is compromised
Solution Approach 1:
The system dynamically adjusts resin pump output based on real-time monitoring of negative pressure levels and resin front position. The controller continuously modulates the resin pump speed to maintain optimal flow rates that preserve enclosure negative pressure, transitioning from static to dynamic control of the resin introduction process.
Solution Approach 2:
The system implements feedback control by monitoring resin front position via detectors and enclosure pressure via sensors, then using this information to adjust resin pump output. This closed-loop control ensures that resin introduction speed is automatically regulated to maintain both productivity and fibre pack compaction.
2Reliability
If resin flow rate is controlled to maintain negative pressure, then fibre pack compaction is preserved, but resin introduction speed must be regulated
Solution Approach 1:
The system employs dynamic flow control where the resin pump operates at variable speeds rather than fixed rates. The controller continuously adjusts pump output to match the exact flow rate needed to maintain negative pressure and fibre pack compaction, optimizing both reliability and productivity throughout the infusion process.
Solution Approach 2:
The system changes operational parameters (resin pump speed, flow rate) in real-time based on monitoring data. By dynamically adjusting these parameters, the system maintains fibre pack compaction while optimizing resin introduction speed for maximum productivity at each stage of the infusion process.
3Productivity
If multiple resin ports are used to increase resin introduction, then resin distribution improves, but control complexity increases
Solution Approach 1:
The system divides the resin introduction function across multiple resin ports, each independently controllable. This segmentation allows resin to be introduced at multiple locations simultaneously, improving distribution efficiency and productivity while the controller manages each port's flow independently to maintain overall system simplicity.
Solution Approach 2:
The controller serves multiple functions by simultaneously monitoring resin front position, enclosure pressure, and regulating flow through multiple resin ports. This multi-functionality consolidates control complexity into a single intelligent device rather than requiring separate control systems for each port.
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 system achieves precise control of resin flow, ensuring the fibre pack remains compacted and the mould enclosure maintains negative pressure, resulting in accurate shape formation of large composite articles.
Implementation Method 1
Air is pumped out from the interior of the mould enclosure via one or more evacuation ports
Implementation Method 2
Resin is driven by applying a pressure differential, typically through the use of a resin pump and/or a vacuum pump
Implementation Method 3
Resin is driven by applying a pressure differential, typically through the use of a resin pump and/or a vacuum pump
Implementation Method 4
the controller determines a position of the resin front relative to one or more subsequent resin ports by determining at least one resin spread parameter
Implementation Method 5
the system comprises at least one resin spread detector for detecting spread of resin within the fibre pack
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Apparatuses, devices, systems (1) and methods for resin transfer moulding of composite articles are disclosed. A mould enclosure enclosing a fibre pack (9) is provided and one or more resin ports (6a-6e) are provided along a resin flow path within the fibre pack (9). Resin ingress into the fibre pack (9) is controlled via valves (44a-44e) or a flow control mechanism (30), each being operable to impose a flow rate on resin passing into the fibre pack (9).