Data processing: measuring – calibrating – or testing – Measurement system in a specific environment – Mechanical measurement system
Reexamination Certificate
2000-07-14
2003-06-10
Barlow, John (Department: 2863)
Data processing: measuring, calibrating, or testing
Measurement system in a specific environment
Mechanical measurement system
C324S649000
Reexamination Certificate
active
06577958
ABSTRACT:
BACKGROUND OF THE INVENTION
Liquid Composite Molding (LCM) processes, such as Resin Transfer Molding (RTM) and Structural Reaction Injection Molding (SRIM), are manufacturing methods for fabricating high-strength, high-volume composite parts. Composite parts are still generally cured in autoclaves, ovens, or presses using empirically based “recipe” cures. Most previous attempts to solve the problems inherent in recipe cures have concentrated on reducing batch-to-batch variations in raw materials and pre-production “proof” processing to accommodate those variations. This approach has been only moderately successful, and not optimally cost effective. Current studies of multi-regional flow in LCM processes do not determine actual flow front location using real-time sensor data during the process. These studies simulate the resin flow using material and process parameters, including permeability, injection pressure, vacuum pressure, and port and vent locations. They often record the resin flow on the surface of the composite on video to compare to simulations.
The present invention accurately determines the actual flow area and location of the flow front in a short time relative to the speed of the flow front. It is not a simulation of the flow using material and process parameters before actual fabrication. Thus, the actual state of fill of the composite in relation to the ports and vents in the mold cavity is known throughout the fabrication process. The present invention can also determine flow front velocity. Since location, speed, and direction fully describe flow in the immediate future, the present invention can be used as the basis of a control methodology capable of modifying the actual condition of the material in real-time or near real-time as it is being processed. Intelligent process control would respond relatively quickly to analysis results to modify flow parameters, e.g., port injection pressure, activation/shut off of injectors, etc.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an apparatus and associated methodology to monitor and display the resin flow during fabrication of organic matrix composite laminates.
The foregoing object is achieved by integration of novel sensor technology, network-based data acquisition, fast finite element based reconstruction (smoothing) and contouring algorithms, and scientific visualization tools. The invention uses a robust combination of data analysis and data visualization techniques to accurately show the entire composite laminate and the flow in the laminate in an easily understood three dimensional display. The invention can display the flow area or the flow front. Either mode of display is easily interpretable without requiring any detailed knowledge of the acquisition, reconstruction, and visualization methodology.
REFERENCES:
patent: 5097432 (1992-03-01), Harada et al.
patent: 5210499 (1993-05-01), Walsh
Development and Testing of an Interface for Real-Time Visualization of Resin Flow in Composites, William Green, Dale Shires and Shawn Walsh, ARL-TR-1784 Sep. 1998.
Green William H.
Shires Dale R.
Walsh Shawn M.
Barlow John
Clohan, Jr. Paul S.
Dougherty Anthony
Randolph William W.
The United States of America as represented by the Secretary of
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