Segmented Resin Transfer Molding Mold for Composite Parts
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Solution Overview
Problem
Traditional resin transfer molding and infusion processes require heavy, specific, and costly tooling, limiting the production of complex composite parts with short tool lifespan and high production costs.
Innovation Solution
A device with a subdivided manufacturing mold featuring a matrix and mobile structural elements that adapt to part shapes, allowing for flexible and replaceable tooling, combined with resin injection means for transverse and laminar impregnation, and a sealing system to ensure resin distribution and polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional RTM or resin infusion molding processes are used with closed molds, then composite parts can be manufactured with proper resin impregnation, but the tooling becomes heavy, complex, and costly with limited lifespan
Solution Approach 1:
The mold is divided into a fixed matrix and separate mobile structural elements that can be independently replaced. This segmentation allows the complex tooling to be broken into manageable components, reducing overall device complexity while maintaining manufacturing reliability through modular replacement of worn elements.
Solution Approach 2:
The patent introduces mobile structural elements that can be indexed and repositioned on the matrix, transforming the static mold into a dynamic system. This allows the same mold base to adapt to different part shapes and sizes, reducing tooling complexity for producing varied parts while ensuring reliable resin impregnation through optimized structural element placement.
2Ease of manufacture
If traditional closed molds are used for RTM or resin infusion, then parts can be manufactured, but tooling costs are high and tooling lifespan is limited
Solution Approach 1:
By segmenting the mold into a durable fixed matrix and replaceable mobile structural elements, the patent enables cost-effective maintenance. When wear occurs, only the mobile elements need replacement rather than the entire mold, significantly reducing repair costs and extending overall tooling lifespan while maintaining part production capability.
Solution Approach 2:
The mobile structural elements are designed to be replaceable and reindexable on the same matrix. When a structural element becomes worn or when different part geometries are needed, the element can be discarded and replaced with a new one, recovering the investment in the durable matrix while minimizing replacement costs.
3Manufacturing precision
If specific molds are designed for specific part shapes, then manufacturing precision can be achieved, but adaptability to different part shapes is limited
Solution Approach 1:
The mobile structural elements can be indexed to different positions and orientations on the matrix, allowing the same mold to adapt to various part shapes and sizes. This dynamic reconfiguration capability maintains manufacturing precision for each specific part geometry while providing versatility across multiple part designs.
Solution Approach 2:
The matrix is designed as a universal base that can accommodate multiple types of mobile structural elements in various configurations. This multi-functionality allows a single mold to produce different part shapes and sizes by reindexing the structural elements, achieving both precision for each part type and adaptability across multiple part designs.
4Manufacturing precision
If distributed injection means are used for resin impregnation, then resin diffusion is improved, but device complexity increases
Solution Approach 1:
The injection system is segmented into multiple distributed injection points across the mold surface. This segmentation improves resin impregnation uniformity by ensuring even resin distribution throughout the preform, while the modular nature of the segmented injection system actually reduces overall complexity compared to a single complex injection mechanism.
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 reduces tooling costs, simplifies the molding process, and extends tool longevity, enabling the production of complex composite parts with reduced production time and improved dimensional accuracy.
Implementation Method 1
injection means suitable for carrying out a mixed impregnation of the preform with injected resin; the injection means are distributed over the surface of the mold so that it favors the diffusion of the resin transversely and/or laminarly
Implementation Method 2
A resin is then injected into the mold and then polymerized by supplying it with energy. The molecules of this resin then begin to bind together and form a solid network.
Data Source
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Figure 3
AI summary
The invention related to a device for making a part of a composite material by resin-transfer molding, that includes a manufacturing mold in which is placed a blank of the part to be impregnated with resin, characterized in that the manufacturing mold is divided into a matrix and one or more mobile structural member to be indexed on the matrix, the whole defining, after assembly, an imprint corresponding to the shape of the part to be manufactured.