Resin Infusion Sensor for Aircraft Composite Parts

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Solution Overview

Problem

Current methods for fabricating aircraft parts using composite materials face challenges in accurately detecting when a preform is fully infused with resin, leading to potential dry zones and inconsistencies in part thickness and mechanical properties due to uncertainties in resin quantity and flow control.

Innovation Solution

Incorporating a permeable layer with lower resin permeability than the preform, positioned remotely from the preform, and using a resin presence sensor to ensure complete impregnation before resin reaches additional layers, along with a sensor capable of detecting resin presence and curing status, to control the resin injection process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If resin is injected into the preform using conventional methods, then the preform is filled with resin, but it is difficult to detect when the preform has finished being filled, leading to uncertainties in resin quantity and potential dry zones

Engineering Contradiction:

Improvedetection of resin filling completionVSAvoidcontrol of resin quantity

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

A sensor is introduced as an intermediary element between the resin and the detection system. The sensor detects the presence of resin through its permeable layer, providing accurate real-time information about resin filling status without directly contacting the resin or requiring complex measurement systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system implements feedback control by continuously monitoring resin presence through the sensor and adjusting the injection process accordingly. When the sensor detects resin presence, the system can determine when the preform is fully filled and stop injection, ensuring accurate resin quantity control.

Inventive Principle:

Principle #23Feedback

2Reliability

If the quantity of resin injected is increased to ensure complete filling, then dry zones are prevented, but the thickness of the part increases due to resin remaining in the mold

Engineering Contradiction:

Improveavoidance of dry zonesVSAvoidcontrol of part thickness

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The sensor provides real-time feedback on resin presence, allowing the injection system to stop precisely when the preform is fully filled. This prevents both under-filling (dry zones) and over-filling (excessive thickness) by basing the decision on actual resin presence detection rather than theoretical calculations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical measurement methods (weighing injection vessels, measuring flow rates) with a sensor-based detection system that directly senses resin presence. This substitution provides more accurate and reliable control over resin quantity, eliminating the need to rely on indirect mechanical measurements that are prone to error.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a semi-permeable membrane is used to confine resin, then resin remains in the mold, but it is difficult to detect when resin flow has stopped due to measurement inaccuracies and potential leaks

Engineering Contradiction:

Improveconfine resin within moldVSAvoiddetection of resin flow cessation

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The sensor acts as an intermediary that directly senses resin presence through the permeable layer, providing a reliable detection method that is not affected by the semi-permeable membrane or potential leaks in the resin circuit. The sensor detects resin presence directly, eliminating the need to rely on indirect flow rate measurements.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 ensures precise control over resin quantity and distribution, preventing dry zones and improving the reliability of composite part fabrication by ensuring complete impregnation before resin reaches additional layers, thus enhancing the mechanical properties and consistency of the final product.

Implementation Method 1

placing in a stack comprising a preform at least one layer of a material that presents permeability to a predetermined resin that is less than the permeability of a portion of the preform that is the closest to the layer

Methodology Applied

Scientific EffectPermeability difference: Permeation

Implementation Method 2

placing a resin presence sensor on a side of the layer that is remote from the preform

Methodology Applied

Scientific EffectResin presence detection:

Data Source

PatentUS9272470B2Method of fabricating an aircraft part by infusing resin

Publication Date: 2016.03.01 AIRBUS OPERATIONS (SAS)

AI summary

The method of fabricating an aircraft part comprises the steps of placing in a stack comprising a preform at least one layer of a material that presents permeability to a predetermined resin that is less than the permeability of a portion of the preform that is the closest to the layer; and placing a resin presence sensor on a side of the layer that is remote from the preform.