Online Stoichiometry Control in Resin Mixing and Metering
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Solution Overview
Problem
Current mono-component thermosetting resin systems for composite structures face limitations in scalability due to stability issues, leading to complex and costly supply chains, safety concerns, and quality control challenges, particularly in aerospace applications, where precise control of resin composition is critical but difficult to achieve with batch processes and off-line analysis.
Innovation Solution
Implementing an online analytical tool within multi-component mixing and metering equipment that uses IR, NIR, refractive index, or UV/VIS measurements to continuously monitor and adjust the mass and volume ratios of thermosetting resin and curing agents before infusion, enabling real-time quality control and ensuring accurate formulation before mold curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch processes with off-line quality control are used for mono-component resin systems, then packaging size is limited to 5-10 kg for safety and stability, but supply chain complexity and costs increase
Solution Approach 1:
The patent segments the resin system into separate components (resin and curative) that are stored independently and mixed on-demand at the point of use. This eliminates the need to transport and store pre-mixed formulations in limited 5-10 kg packages, allowing bulk storage of stable individual components while maintaining process safety through controlled mixing ratios enabled by the online analytical tool.
Solution Approach 2:
The system performs preliminary preparation by storing pure resin and curative components separately in bulk quantities before the actual infusion process. The online analytical tool enables real-time formulation control during mixing, eliminating the need for pre-mixed batches and their associated quality control steps, thus simplifying the supply chain while maintaining reliability.
2Ease of operation
If mono-component resin systems are used with packaging limited to 5-10 kg, then transport and storage restrictions are reduced, but viscosity changes over time due to chemical crosslinking occur
Solution Approach 1:
By separating the resin and curative into distinct components stored in separate tanks, the patent prevents premature chemical crosslinking that causes viscosity increase. Each component remains stable during storage and transport, and only undergoes reaction when mixed in precise ratios controlled by the online analytical tool during the infusion process.
Solution Approach 2:
The online analytical tool provides real-time feedback on the composition and mixing ratio of the resin system. This enables continuous monitoring and adjustment to maintain optimal viscosity and formulation quality, compensating for any variations in raw materials or environmental conditions that might affect the reaction process.
3Duration of action of stationary object
If cold storage at -18° C. is implemented for mono-component resins, then shelf life is extended, but processing complexity and energy consumption increase
Solution Approach 1:
The patent eliminates the need for cold storage by segmenting the resin system into separate stable components that can be stored at ambient temperatures. The resin and curative remain chemically inactive when separated, extending their usable life without requiring energy-intensive refrigeration, while maintaining formulation stability through controlled mixing.
Solution Approach 2:
The system changes the storage parameters from cold temperature (-18° C.) to ambient temperature by fundamentally altering the chemical state of the system. Individual components are stored in their stable, non-reactive forms at higher temperatures, and the reactive state is achieved only temporarily during the infusion process through controlled mixing in precise ratios.
4Ease of operation
If pre-heating to 60-80° C. is used for refilling small scale packages, then material flowability is improved, but quality and safety risks increase due to reactivity
Solution Approach 1:
By keeping resin and curative separate and only mixing them in precise ratios controlled by the online analytical tool during infusion, the system avoids the quality and safety risks associated with pre-heating and refilling. The components are delivered at controlled temperatures without premature reaction, and mixing occurs only when needed in the exact stoichiometric proportions required.
Solution Approach 2:
The patent replaces the mechanical/refilling-based system with an automated continuous mixing system controlled by online analytical tools. This eliminates the need for manual pre-heating and refilling operations, providing more precise control over temperature, mixing ratios, and timing, thereby improving both safety and quality.
5Manufacturing precision
If multi-component mixing and metering equipment with online analytical tool is implemented, then manufacturing precision of resin formulation is improved, but device complexity increases
Solution Approach 1:
The online analytical tool provides real-time feedback on the composition, mixing ratio, and quality of the resin formulation. This closed-loop control system automatically adjusts the mixing parameters to maintain precise stoichiometric ratios, compensating for variations in raw materials, temperature, or flow rates, thereby achieving high manufacturing precision through intelligent control rather than mechanical complexity.
Solution Approach 2:
The mixing and metering equipment is designed with multi-functionality, integrating metering, mixing, heating, and online analytical monitoring in a single system. This universal device handles multiple functions that would otherwise require separate equipment, reducing overall system complexity while maintaining precise formulation control through centralized management.
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 solution reduces costs and safety risks, eliminates the need for cold storage, allows for higher-quality products with improved thermal stability, and significantly decreases the number of out-of-specification goods by enabling precise, continuous monitoring and adjustment of the resin composition during the infusion process.
Implementation Method 1
Implementing an online analytical tool within multi-component mixing and metering equipment that uses IR, NIR, refractive index, or UV/VIS measurements to continuously monitor
Implementation Method 2
Implementing an online analytical tool within multi-component mixing and metering equipment that uses IR, NIR, refractive index, or UV/VIS measurements to continuously monitor
Implementation Method 3
Implementing an online analytical tool within multi-component mixing and metering equipment that uses IR, NIR, refractive index, or UV/VIS measurements to continuously monitor
Implementation Method 4
Implementing an online analytical tool within multi-component mixing and metering equipment that uses IR, NIR, refractive index, or UV/VIS measurements to continuously monitor
Data Source
AI summary
The invention describes an advanced mixing and metering technology with online analytics for a supply of formulated liquid thermosetting resins into an open or closed mold. The application addresses where a precise control of the composition of formulated components is required. Composite structures used in primary and secondary structural aerospace applications manufactured in Infusion or RTM processes are possible examples.