Variable Matrix Composite Resin Infusion
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Solution Overview
Problem
Existing composite materials lack the ability to create structures with varying properties throughout, making it difficult to achieve localized enhancements in characteristics such as toughness, strength, and weight distribution, which are essential for aerospace applications.
Innovation Solution
The method involves using a single vacuum assisted resin transfer molding process to infuse two or more different resins with distinct properties into a composite material, creating a transition region and varying material characteristics along the length, thickness, and in isolated areas, utilizing localized resin infusion and interstitial plies to achieve specific properties where needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single resin is used throughout the composite structure, then the manufacturing process is simple and uniform, but the structure cannot achieve localized enhancements in toughness, strength, and weight distribution
Solution Approach 1:
The patent applies local quality by infusing different resins with distinct properties into specific regions of the composite structure. The first resin provides base structural properties while the second resin enhances localized areas with improved toughness, strength, or weight characteristics. This allows different parts of the same composite structure to have tailored properties according to specific performance requirements.
Solution Approach 2:
The manufacturing process is segmented into multiple resin infusion stages. The first resin is infused initially to establish the base structure, followed by a second resin infusion to add localized enhancements. This segmentation allows complex multi-property structures to be built through sequential, controlled resin applications rather than requiring a single complex infusion process.
2Strength
If multiple resins with distinct properties are infused into the composite material, then localized enhancements in toughness, strength, and weight distribution are achieved, but the manufacturing process complexity increases
Solution Approach 1:
The patent implements local quality by selectively infusing the second resin with enhanced properties into specific regions where strength, toughness, or weight optimization is required. The first resin forms the base composite structure, while the second resin creates localized zones of enhanced performance, allowing strength enhancement exactly where needed without compromising other areas.
Solution Approach 2:
The first resin is infused and allowed to partially cure or stabilize the composite structure before the second resin infusion. This preliminary action establishes a stable base structure that can then receive the second resin infusion, ensuring that the enhanced strength properties are properly integrated into an already-stabilized composite matrix rather than attempting to manage multiple resins simultaneously.
3Reliability
If a transition region is created between different composite materials, then property gradients and damage tolerance are improved, but the manufacturing process requires additional vacuum lines and process steps
Solution Approach 1:
The transition region is created by controlling the infusion of the second resin to form a gradient zone between the first composite material and the second composite material. This local quality variation in the transition region provides property gradients that improve damage tolerance by gradually transitioning between different material properties rather than creating abrupt interfaces, reducing stress concentration and crack propagation risks.
Solution Approach 2:
The patent merges multiple functions into a single integrated vacuum-assisted resin transfer molding process. The first and second resin infusions, along with the creation of the transition region, are all accomplished within one continuous manufacturing cycle using coordinated vacuum lines. This combining of operations maintains productivity by avoiding separate manufacturing steps while still achieving the reliability benefits of transition regions.
4Adaptability or versatility
If different composite material characteristics are used in different regions, then tailored performance is achieved, but the number of components and assembly steps increases
Solution Approach 1:
The patent merges multiple composite material regions with different characteristics into a single integrated composite structure. By using sequential resin infusions of the first and second resins with distinct properties, the manufacturing process creates a monolithic structure containing zones of different material characteristics, eliminating the need for separate components and their associated assembly steps while maintaining tailored performance across different regions.
Solution Approach 2:
The single composite structure achieves multi-functionality by incorporating different resin-infused regions within one unified component. The first resin provides base structural functions while the second resin adds enhanced properties in specific areas, allowing one component to perform multiple functions that would traditionally require several separate parts, thereby reducing assembly complexity while maintaining adaptability.
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 allows for the creation of composite structures with tailored properties, enhancing toughness, damage tolerance, and impact absorption, reducing the number of components and improving aerodynamics and acoustics, while maintaining structural integrity.
Implementation Method 1
A prior art method of making a composite structure with the features of the preamble to claim 1 is disclosed in US 2008/305340. Other prior art methods of making a composite structure are disclosed in WO 2010/040359 and EP 2 620 265.
Implementation Method 2
The transition region, the first composite material and the second composite material may be formed in a single vacuum assisted resin transfer molding process.
Data Source
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AI summary
The present disclosure includes composite materials and/or aircraft components. A method is disclosed for fabricating a composite component with varying properties for at least one of the following: along its length, through its thickness, radially, or in isolated areas. The method includes drawing a first resin (5) from a first resin source over a first section (160) of plies of material in a mold (100) by a first vacuum line (170); drawing a second resin (20) from a second resin source over a second section (150) of plies of material in the mold (100) by the first vacuum line (170); and curing the first resin (5) and the second resin (20); wherein a transition region, a first composite material and a second composite material are formed in response to the curing of the first resin (5) and the second resin (20). The embodiments may be used with Vacuum Assisted Resin Transfer Molding (VARTM), Resin Film Infusion (RFI), and/or Pre-Impregnated Fabric (Pre-Preg).