Void Analysis in Porous Resin Impregnation
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Solution Overview
Problem
Current technologies lack a comprehensive method to analyze and minimize the production, growth, and distribution of voids in resin during the impregnation and molding of porous materials, which can lead to strength degradation in lightweight and high-strength products like fiber-reinforced plastics, due to gas generation from the porous material, solid member, and resin during heating and curing.
Innovation Solution
A method that measures changes in gas generation, compressive forces, and flow resistance over time and temperature, incorporating these parameters into a fluid analysis program to estimate void production and growth, using finite elements to calculate resin density and viscosity, and adjusting the drying process and resin curing conditions to minimize void formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure is applied to discharge voids during resin impregnation, then void removal is improved, but dielectric breakdown occurs due to gas discharge through voids
Solution Approach 1:
The patent applies preliminary drying treatment to the porous material before resin impregnation to remove most gas content in advance. This preliminary action prevents gas discharge during subsequent high-pressure resin injection, thereby avoiding dielectric breakdown while still achieving effective void removal through the drying process and controlled resin impregnation.
2Manufacturing precision
If experimental review of drying process and resin heating conditions is performed to minimize void generation, then void production is reduced, but development time and cost increase
Solution Approach 1:
The patent creates a computational model that replicates the resin impregnation and curing process virtually. This digital copy allows systematic review and optimization of drying process parameters and resin heating conditions without requiring repeated physical experiments. The model simulates gas generation, resin flow, and void formation, enabling rapid identification of optimal parameters that minimize void production while reducing development time.
3Measurement precision
If comprehensive analysis of void production, growth, fluid behavior, and distribution is performed, then void estimation accuracy is improved, but analysis complexity increases
Solution Approach 1:
The patent divides the porous material into multiple finite elements for systematic analysis. Each element can be independently analyzed for void production, growth, and resin fluid behavior. This segmentation allows the complex three-dimensional problem to be broken down into manageable calculations, improving estimation accuracy while keeping the analysis approach structured and systematic rather than overly complex.
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 enables comprehensive estimation and minimization of voids in resin, improving product reliability, reducing development time, and lowering production costs by optimizing the drying and curing processes and material modifications.
Implementation Method 1
a resin flow in a porous material, a technology for a calculation method of inputting a three-dimensional pressure loss as a product of a cross-sectional specific resistance representing a flow resistance, a viscosity, a velocity, and a flow distance
Implementation Method 2
Production and growth of voids are attributable to gas generated at the time of heating a porous material in which an organic solvent remains, a solid member that contains an organic substance and adjoins the porous material and a resin, and a resin material
Implementation Method 3
changes in a compressive force and a compressive displacement respectively occurring when the porous material filled with or impregnated with a resin is compressed
Data Source
AI summary
The present invention provides a method for analyzing growth of void of resin in a porous material which comprising the steps of inputting data of the shape of a porous material filled with a resin material, and dividing the shape of the porous material into three-dimensional solid elements; inputting physical properties of the porous material, and boundary conditions including a pressure that is applied to the porous material; obtaining a resin-density distribution in the porous material through fluid analysis using a database obtained by experimentally measuring in advance a temporal change in a volume of gas generated from the resin material and porous material during heating, changes in a compressive force and compressive displacement respectively occurring when the porous material impregnated with the resin is compressed, and a change in a flow resistance of the resin; and comprehensively grasping production, growth, and distribution of voids deriving from gas generation.