Selective Curing of Fiber-Reinforced Composite Preforms

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Solution Overview

Problem

Current methods for manufacturing complex three-dimensional structures, such as vehicle bodies, require multiple separately cured components to be bonded together, leading to increased complexity, waste, and limited access for internal component installation, especially during the final assembly stage.

Innovation Solution

A method involving a preform of fibre-reinforced material that is selectively cured in a first configuration to create an intermediate preform with rigid and flexible sections, allowing for manipulation into a three-dimensional shape without the need for separate bonding, reducing the number of joints and enabling easier access for internal component installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple separately cured components are bonded together to form complex three-dimensional structures, then the structural integrity and strength are improved, but the manufacturing complexity and time increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The preform is selectively cured in different regions to create rigid portions and flexible hinge portions, segmenting the structure into movable and fixed sections that can be assembled into complex three-dimensional shapes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The preform is partially cured in advance to create rigid sections connected by flexible hinges, allowing the structure to be manipulated into its final three-dimensional configuration before complete curing, thereby simplifying the assembly process

Inventive Principle:

Principle #10Preliminary action

2Strength

If multiple separately cured components are bonded together to form complex three-dimensional structures, then the structural integrity is improved, but the manufacturing time is increased

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Multiple curing operations on separate components are merged into a single selective curing process applied to one continuous preform, reducing the total manufacturing time while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If a single preform is selectively cured to create rigid and flexible sections, then the manufacturing complexity is reduced, but the curing process complexity increases

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidcuring process complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

Different regions of the preform are subjected to different curing conditions, with some regions fully cured to create rigid portions and other regions partially cured to maintain flexibility in hinge sections

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The curing process parameters (temperature, time, pressure) are varied across different regions of the preform to achieve the desired degree of curing in each section, transforming a uniform process into a spatially differentiated one

Inventive Principle:

Principle #35Parameter changes

4Strength

If separate components are bonded together to form the final structure, then the structural strength is improved, but the number of joints and potential weak points increases

Engineering Contradiction:

Improvestructural strengthVSAvoidjoint reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

Multiple separate components are merged into a single continuous preform that is selectively cured, eliminating the need for bonding joints between separate parts and creating a monolithic structure with improved reliability

Inventive Principle:

Principle #5Merging (Combining)

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 manufacturing time and complexity, minimizes waste by using a single preform to create the structure, and enhances the strength of the final product by allowing for a two-stage curing process, improving the overall efficiency and accessibility during the manufacturing process.

Implementation Method 1

selectively curing the preform when laid out on the support structure to produce an intermediate preform

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS10987833B2Manufacturing fiber-reinforced composite structures

Publication Date: 2021.04.27 FORTESCUE ZERO LTD

AI summary

The invention relates to a method of manufacturing a three dimensional structure having an internal space, the method comprising the following steps: (a) arranging a preform of fibre reinforced material in a first configuration in which the preform is supported by a support structure; (b) selectively curing the preform when laid out on the support structure to produce an intermediate preform, the intermediate preform comprising at least two selectively cured portions interconnected by at least one non-selectively cured portion; and (c) moving the two selectively cured portions with respect to one another to form the three dimensional composite structure in which the two portions at least partially surround the internal space of the structure. A preform of fibre reinforced material for use in a method of manufacturing a three dimensional structure having an internal space also forms part of the invention. The invention also relates to a device and intermediate preforms for the manufacture of a fibre-reinforced composite structure.