Segmented Vacuum Bagging Layer Assembly for Composite Gas Evacuation
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Solution Overview
Problem
Conventional composite manufacturing techniques require thick material stacks for gas evacuation and resin movement, leading to challenges in applying uniform compaction pressure, especially in parts with tight geometry, and are labor-intensive and time-consuming due to mechanical fastening processes.
Innovation Solution
A vacuum bagging system with a layer assembly forming a fluid flow channel, including a contact layer and an inner layer, positioned within an outer mold line tool, allowing for a low-thickness path for gas evacuation and resin movement, which reduces the need for mechanical fastening and multiple consolidation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional composite tools use thick material stacks for gas evacuation, then gas evacuation path is provided, but uniform compaction pressure application becomes difficult
Solution Approach 1:
The vacuum bagging system is segmented into multiple functional layers: a contact layer with thickness of 0.002 to 0.006 inches for gas evacuation, and an inner layer with thickness of 0.006 to 0.020 inches for resin movement. This segmentation allows each layer to perform its specific function with optimized thickness, eliminating the need for a single thick material stack while enabling uniform compaction pressure application.
Solution Approach 2:
Different regions of the vacuum bagging system have different thicknesses and material properties tailored to local requirements. The contact layer has minimal thickness (0.002 to 0.006 inches) where gas evacuation is needed, while the inner layer has greater thickness (0.006 to 0.020 inches) where resin movement is required. This local differentiation enables both functions to be performed effectively without compromising uniform compaction pressure.
2Reliability
If conventional methods use multiple consolidation steps, then composite parts are consolidated, but processing time and labor increase
Solution Approach 1:
The vacuum bagging system merges gas evacuation and resin movement functions into a single integrated multi-layer structure. The contact layer handles gas evacuation while the inner layer facilitates resin movement, allowing both consolidation functions to occur simultaneously in one step rather than requiring multiple separate consolidation steps, thereby reducing processing time and labor while maintaining consolidation quality.
Solution Approach 2:
The multi-layer vacuum bagging system performs multiple functions simultaneously: the contact layer provides gas evacuation, the inner layer enables resin movement, and together they apply uniform compaction pressure. This multi-functionality eliminates the need for separate consolidation steps for each function, significantly improving productivity while maintaining reliable consolidation quality.
3Length of moving object
If conventional tools require thick material stacks, then gas evacuation is enabled, but the need for mechanical fastening increases
Solution Approach 1:
The thick material stack is segmented into thin functional layers: a contact layer (0.002 to 0.006 inches) and an inner layer (0.006 to 0.020 inches). This segmentation reduces the overall thickness requirement while providing specialized functions for each layer, enabling gas evacuation and resin movement without requiring thick stacks that would necessitate mechanical fastening.
Solution Approach 2:
The system replaces mechanical fastening with a thin multi-layer vacuum bagging structure that achieves gas evacuation and resin movement through its layered configuration. The contact layer with thickness of 0.002 to 0.006 inches provides the necessary gas evacuation path without requiring mechanical fasteners, substituting a mechanical system with a streamlined material-based solution.
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
Enables efficient evacuation of gases and uniform compaction pressure in complex geometries, reducing processing time and labor by minimizing material thickness and eliminating the need for mechanical fastening, resulting in accurately formed composite parts with improved dimensional accuracy.
Implementation Method 1
The path may also be required for resin movement when the composite material is heated to allow for uniform compaction pressure of the composite part against the tool surface
Implementation Method 2
when the composite material is heated to allow for uniform compaction pressure of the composite part against the tool surface
Data Source
AI summary
A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.