Variable Adhesive Density Preform for Composite Curvature
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Solution Overview
Problem
The existing resin transfer molding (RTM) method for composite materials restricts the shape flexibility of preforms due to adhesive fixation, making it difficult to mold shapes with large curvature, which can lead to wrinkles or twists, thereby limiting the shape selection range of the composite material.
Innovation Solution
A manufacturing method and apparatus that apply adhesive to sheet-shaped reinforcements with varying content densities, where the second region has a lower adhesive density than the first region, allowing for easier deformation and shaping of preforms with larger curvatures, thereby suppressing wrinkles and twists.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive is applied uniformly to fix reinforcement layers, then fiber arrangement deviation is suppressed, but preform shape flexibility is restricted and wrinkles/twists occur in high curvature portions
Solution Approach 1:
The adhesive application amount is varied by region: high application amount in first regions (low curvature portions requiring fixation) and low application amount in second regions (high curvature portions requiring flexibility). This local differentiation resolves the contradiction by providing fixation where needed while maintaining deformability where curvature requires flexibility.
Solution Approach 2:
The reinforcement is divided into multiple regions (first regions and second regions) with different adhesive application characteristics. This segmentation allows different portions of the same reinforcement to have different degrees of freedom, enabling both fixation and flexibility within the same preform structure.
2Stability of the object's composition
If adhesive content density is increased to suppress fiber deviation, then fiber arrangement stability is improved, but deformation capability in high curvature regions deteriorates
Solution Approach 1:
Different adhesive content densities are applied to different regions: high content density in first regions for stability and low content density in second regions for deformability. This local quality differentiation allows the reinforcement to simultaneously achieve both stability and ease of deformation in appropriate locations.
Solution Approach 2:
The adhesive content density parameter is changed across different regions of the reinforcement. By varying this parameter spatially (high in first regions, low in second regions), the reinforcement achieves different mechanical properties in different locations, resolving the contradiction between stability and deformability.
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 enhances the shape flexibility of preforms, expanding the shape selection range of composite materials while maintaining fiber arrangement accuracy, enabling the production of complex shapes without deformation issues.
Implementation Method 1
an adhesive is applied to a sheet-shaped reinforcement having first and second regions such that a content density of the adhesive of the second region is lower than that of the first region
Data Source
AI summary
To provide a manufacturing method for a composite material, a manufacturing apparatus for a composite material, a preform, and a composite material, capable of molding a high quality composite material having a little constraint in the shape by improving moldability while suppressing a deviation of the arrangement of the reinforced fiber during preforming. A manufacturing method for a composite material 400 provided with a reinforcement 510 and resin 600 infused into the reinforcement, includes: an apply process (step S12) for applying an adhesive to the sheet-shaped reinforcement having first and second regions 511 and 512 such that a content density of the adhesive 520 of the second region is lower than that of the first region; and a preforming process (step S17) for preforming the reinforcement in a three-dimensional shape to form a preform such that the second region has a curvature larger than that of the first region.