MOULD ASSEMBLY AND METHOD FOR FABRICATING FUNCTIONALLY GRADED HYBRID FIBER REINFORCED POLYMER COMPOSITES

Abstract

Disclosed is a mould assembly (100) for fabricating functionally graded hybrid fiber reinforced polymer composites. The mould assembly includes a bottom plate (102), a top plate (104), a first supporting fixture (110) and a second supporting fixture (112) attached to opposite sides of the bottom plate, and a first slider (106) and a second slider (108) movably connected to the first and second supporting fixtures, respectively. Each supporting fixture includes a groove (114) for accommodating the respective slider. The first and second sliders are configured to move horizontally along the grooves to facilitate functional gradation of fibers during composite fabrication. The mould assembly enables a method for fabricating functionally graded composites by adjusting slider positions to create distinct fiber zones in multiple layers, followed by curing and removal of the fabricated composite.

Specification

Description:FIELD OF DISCLOSURE
The present disclosure relates to mould assemblies for composite fabrication, and more particularly to a mould assembly and method for fabricating functionally graded hybrid fiber reinforced polymer composites.
BACKGROUND
Fiber-reinforced polymer (FRP) composites have gained significant attention in various industries due to their unique advantages over conventional materials like concrete and steel. These composites are manufactured by combining fibers, either synthetic or natural, with a polymer matrix such as epoxy resin. FRP composites offer high strength-to-weight ratios, corrosion resistance, and design flexibility, making them suitable for applications in aerospace, automotive, construction, and marine industries.
In recent years, there has been growing interest in hybrid FRP composites, which combine two or more types of fibers to achieve enhanced mechanical properties. These hybrid composites can be fabricated in various configurations, such as sandwich hybrids or alternating layer hybrids. However, a more advanced form of hybrid composites, known as functionally graded hybrid (FH) composites, has emerged as a promising material. FH composites feature varying material properties along their thickness, offering unique advantages in terms of strength, stiffness, and ductility. Despite their potential benefits, the manufacturing process for FH composites presents significant challenges using conventional fabrication methods and equipment.
Current manufacturing techniques for FRP composites, such as hand layup and compression molding, are well-established for producing plain and simple hybrid composites. However, these methods face limitations when attempting to create the precise fiber gradation required for FH composites. Existing molds and equipment are not designed to facilitate the controlled placement of different fiber types within a single layer, leading to difficulties in achieving the desired functional gradation. Additionally, the risk of fiber overlap and improper bonding between different fiber zones can compromise the structural integrity and performance of the final composite.
Therefore, there exists a need for a technical solution that solves the aforementioned problems of conventional systems and methods for fabricating functionally graded hybrid fiber reinforced polymer composites.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In an aspect of the present disclosure, a mould assembly for fabricating functionally graded hybrid fiber reinforced polymer composites is disclosed. The mould assembly includes a bottom plate and a top plate configured to cover the bottom plate. A first supporting fixture and a second supporting fixture are attached to opposite sides of the bottom plate. A first slider and a second slider are movably connected to the first supporting fixture and the second supporting fixture, respectively. The first supporting fixture and the second supporting fixture each include a groove for accommodating the respective slider. The first slider and the second slider are configured to move horizontally along the grooves to facilitate functional gradation of fibers during composite fabrication.
In some aspects of the present disclosure, the first supporting fixture and the second supporting fixture are vertically adjustable relative to the bottom plate.
In some aspects of the present disclosure, the vertical adjustment of the first supporting fixture and the second supporting fixture is facilitated by nuts and bolts connecting the supporting fixtures to the bottom plate.
In some aspects of the present disclosure, the bottom plate includes a plurality of holders for lifting and maneuvering the bottom plate.
In some aspects of the present disclosure, the top plate includes a handle for lifting and positioning the top plate.
In some aspects of the present disclosure, the bottom plate and the top plate include a plurality of connection holes for securing the top plate to the bottom plate.
In some aspects of the present disclosure, the connection holes are arranged around the perimeter of the bottom plate and the top plate to allow for even distribution of pressure when the mould assembly is assembled.
In an aspect of the present disclosure, a method for fabricating a functionally graded hybrid fiber reinforced polymer composite using a mould assembly is disclosed. The method includes placing a thin plastic film over a bottom plate of the mould assembly. A first layer of fiber is positioned on the plastic film and epoxy is applied. A first slider and a second slider of the mould assembly are adjusted to prepare for a subsequent layer. Different fiber types for a second layer are placed, with the sliders positioned to create distinct zones. The sliders are adjusted again and a third layer of fibers is added to continue functional gradation. A final fiber layer is added to complete a composite stack. A top plate of the mould assembly is placed over the stacked composite layers. The assembled mould is cured in an oven. The fabricated composite is removed from the mould assembly.
In some aspects of the present disclosure, adjusting the first slider and the second slider includes vertically adjusting supporting fixtures to which the sliders are attached.
In some aspects of the present disclosure, vertically adjusting the supporting fixtures is facilitated by nuts and bolts connecting the supporting fixtures to the bottom plate.
In some aspects of the present disclosure, placing different fiber types for the second layer includes positioning a first fiber type between the first slider and the second slider, and positioning a second fiber type in gaps between the sliders and edges of the bottom plate.
In some aspects of the present disclosure, adjusting the sliders again for the third layer includes decreasing the distance between the first slider and the second slider to create a narrower zone for the first fiber type.
In some aspects of the present disclosure, the method further includes applying epoxy to each layer of fibers after placement.
In some aspects of the present disclosure, curing the assembled mould includes heating the mould assembly in an oven at a temperature of 80°C for three hours.
In some aspects of the present disclosure, the method further includes allowing the cured composite to cool before removing it from the mould assembly.
The foregoing general description of the illustrative aspects and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.
BRIEF DESCRIPTION OF FIGURES
The following detailed description of the preferred aspects of the present disclosure will be better understood when read in conjunction with the appended drawings. The present disclosure is illustrated by way of example, and not limited by the accompanying figures, in which like references indicate similar elements.
FIG. 1A illustrates an isometric view of a mould assembly for fabricating functionally graded hybrid fiber reinforced polymer composites, according to aspects of the present disclosure;
FIG. 1B illustrates a top view of a bottom plate of the mould assembly of FIG. 1A, according to aspects of the present disclosure;
FIG. 1C illustrates a top view of a top plate of the mould assembly of FIG. 1A, according to aspects of the present disclosure;
FIG. 1D illustrates an isometric view of a partial assembly of the mould assembly of FIG. 1A, according to aspects of the present disclosure;
FIG. 1E illustrates an orthogonal view of the partial assembly of FIG. 1D, according to aspects of the present disclosure;
FIG. 1F illustrates an orthogonal view of another partial assembly of the mould assembly of FIG. 1A, according to aspects of the present disclosure;
FIG. 1G illustrates orthogonal views of the partial assembly of FIG. 1F, according to aspects of the present disclosure;
FIG. 1H illustrates a method for fabricating a functionally graded hybrid fiber reinforced polymer composite, according to aspects of the present disclosure; and
FIG. 2 illustrates a flowchart of a method for fabricating a functionally graded hybrid fiber reinforced polymer composite, according to aspects of the present disclosure.
DETAILED DESCRIPTION
The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.
The present disclosure provides a mould assembly and a method for fabricating functionally graded hybrid fiber reinforced polymer composites. The mould assembly is designed to facilitate the fabrication of thecomposites, which have varying material properties along their thickness. This is achieved by incorporating movable sliders and adjustable supporting fixtures in the mould assembly, which allow for precise control over the placement and gradation of different fiber types within each layer of the composite. The mould assembly also includes top and bottom plates, which can be securely connected to apply compression during the fabrication process. The method for fabricating the composites involves a series of steps including the placement of fibers, adjustment of sliders and supporting fixtures, application of epoxy, and curing of the assembled mould. Themould assembly and method offer a solution to the challenges faced in the manufacturing of functionally graded hybrid composites using conventional techniques and equipment.
FIG. 1A illustrates an isometric view of a mould assembly 100 for fabricating functionally graded hybrid fiber reinforced polymer composites, according to aspects of the present disclosure.
The mould assembly 100 may include a bottom plate 102 and a top plate 104 configured to cover the bottom plate 102. The mould assembly 100 may further include a first supporting fixture 110 and a second supporting fixture 112 attached to opposite sides of the bottom plate 102. A first slider 106 and a second slider 108 may be movably connected to the first supporting fixture 110 and the second supporting fixture 112, respectively. The first supporting fixture 110 and the second supporting fixture 112 may each include a groove 114 for accommodating the respective slider. The first slider 106 and the second slider 108 may be configured to move horizontally along the grooves 114 to facilitate functional gradation of fibers during composite fabrication, wherein the ends of the first slider (106) and second slider (108) are attached with the nuts (122), wherein the nuts (122) are passing through the grooves (114) of the supporting fixtures (110) and (112), wherein the first slider (106) and second slider (108) moves freely on either ways by adjusting the bolts on (122).
The bottom plate 102 may serve as the base for the mould assembly 100, providing a stable foundation for the composite layup process. The bottom plate 102 may be fabricated from a rigid material, such as mild steel, to withstand the pressures and temperatures involved in the composite fabrication process. In some aspects of the present disclosure, the bottom plate 102 may be fabricated from alternative materials, such as high-strength steel alloys or stainless steel, to enhance durability and resistance to corrosion.
The top plate 104 may be designed to cover the composite layup and apply uniform pressure during the curing process. The top plate 104 may be fabricated from the same material as the bottom plate 102 or from a different material with suitable strength and thermal properties. In some aspects of the present disclosure, the top plate 104 may include additional features, such as a textured surface or release coating, to facilitate easy removal of the cured composite.
The first supporting fixture 110 and the second supporting fixture 112 may be vertically adjustable relative to the bottom plate 102. The vertical adjustability may allow for accommodation of different composite thicknesses and facilitate the creation of varying fiber gradations along the thickness of the composite. The vertical adjustment of the first supporting fixture 110 and the second supporting fixture 112 may be facilitated by nuts and bolts 122 connecting the supporting fixtures to the bottom plate 102.
The first slider 106 and the second slider 108 may be designed to move horizontally along the grooves 114 of the supporting fixtures. The horizontal movement may enable precise positioning of fibers during the layup process, allowing for the creation of distinct zones within each layer of the composite. The sliders may be fabricated from a material with low friction properties to ensure smooth movement along the grooves 114.
The grooves 114 in the first supporting fixture 110 and the second supporting fixture 112 may be precision-machined to ensure accurate and consistent movement of the sliders. In some aspects of the present disclosure, the grooves 114 may include a low-friction coating or liner to further enhance the smooth operation of the sliders.
The bottom plate 102 may include a plurality of holders 120 for lifting and maneuvering the bottom plate 102. The holders 120 may be strategically positioned to allow for balanced and safe handling of the mould assembly 100 during setup and composite removal processes.
The top plate 104 may include a handle 118 for lifting and positioning the top plate 104. The handle 118 may facilitate easy placement and removal of the top plate 104 during the composite fabrication process.
The bottom plate 102 and the top plate 104 may include a plurality of connection holes 116 for securing the top plate 104 to the bottom plate 102. The connection holes 116 may be arranged around the perimeter of the bottom plate 102 and the top plate 104 to allow for even distribution of pressure when the mould assembly 100 is assembled. The connection holes 116 may accommodate fasteners, such as bolts or clamps, to securely join the top and bottom plates during the curing process.
In some aspects of the present disclosure, the mould assembly 100 may include additional features such as alignment pins or guides to ensure proper positioning of the top plate 104 relative to the bottom plate 102. Furthermore, the mould assembly 100 may incorporate sealing elements, such as gaskets or O-rings, to prevent resin leakage during the composite fabrication process.
The mould assembly 100 may be designed to accommodate various sizes and shapes of composite parts. In some aspects of the present disclosure, the dimensions of the bottom plate 102, top plate 104, supporting fixtures, and sliders may be customizable to suit specific composite fabrication requirements.
The mould assembly 100 may enable the fabrication of functionally graded hybrid fiber reinforced polymer composites with precise control over fiber placement and gradation. This may result in composites with tailored mechanical properties along their thickness, offering advantages in terms of strength, stiffness, and ductility for applications in aerospace, automotive, construction, and marine industries.
In some aspects of the present disclosure, the first supporting fixture 110 and the second supporting fixture 112 may be vertically adjustable relative to the bottom plate 102. The vertical adjustability may be facilitated by nuts and bolts 122 connecting the supporting fixtures to the bottom plate 102. The vertical adjustment allows for accommodation of different composite thicknesses and facilitates the creation of varying fiber gradations along the thickness of the composite.
The connection holes 116 may be arranged around the perimeter of the bottom plate 102 and the top plate 104 to allow for even distribution of pressure when the mould assembly 100 is assembled. This arrangement ensures uniform compression across the composite during the curing process.
The mould assembly 100 may be fabricated from mild steel. In some aspects of the present disclosure, alternative materials such as high-strength steel alloys or stainless steel may be used to enhance durability and resistance to corrosion.
FIG. 1B illustrates a top view of a bottom plate 102 of the mould assembly 100 of FIG. 1A, according to aspects of the present disclosure.
The bottom plate 102 may be a rectangular structure forming the base of the mould assembly 100. The bottom plate 102 may include a plurality of holders 120, specifically a first holder 120a and a second holder 120b, positioned on opposite sides of the bottom plate 102. The holders 120 may extend outward from the edges of the bottom plate 102, providing convenient points for lifting and maneuvering the bottom plate 102 during the composite fabrication process.
The bottom plate 102 may further feature a plurality of bottom plate holes 124 arranged in a specific pattern. The holes may be distributed around the perimeter of the plate and in two parallel lines in the interior. A first bottom plate hole 124a may be located at one corner of the plate, while an nth bottom plate hole 124n may be positioned at the opposite corner. Thearrangement of holes 124 may serve multiple purposes in the mould assembly 100.
In some aspects of the present disclosure, the bottom plate holes 124 may be used for attaching other components of the mould assembly 100, such as the first supporting fixture 110 and the second supporting fixture 112. The holes may accommodate nuts and bolts 122 for secure attachment and vertical adjustment of the supporting fixtures.
The arrangement of the bottom plate holes 124 may create a rectangular pattern in the center of the bottom plate 102. Such configuration may allow for the placement of materials or other components within the central area of the plate during the composite layup process. In some aspects of the present disclosure, the central area may be designed to accommodate different sizes and shapes of composite parts.
The bottom plate 102 may be fabricated from materials that can withstand the pressures and temperatures involved in composite fabrication. In some aspects of the present disclosure, the bottom plate 102 may be made from materials with specific surface properties to facilitate the release of the cured composite. For example, the surface of the bottom plate 102 may be treated with a release agent or coated with a non-stick material.
In some aspects of the present disclosure, the bottom plate 102 may include additional features not visible in the top view. For instance, the underside of the bottom plate 102 may include reinforcing structures or mounting points for integration with external equipment or support structures.
The design of the bottom plate 102 may allow for versatility in the composite fabrication process. The arrangement of holes and holders may enable the attachment of various accessories or modifications to suit different composite layup requirements. For example, additional guides or stops may be attached to the bottom plate 102 to assist in precise fiber placement.
The bottom plate 102 may be designed to work in conjunction with the top plate 104 to apply uniform pressure during the curing process. The layout of the bottom plate holes 124 may correspond to the connection holes 116 on the top plate 104, allowing for secure and even fastening of the two plates.
In some aspects of the present disclosure, the bottom plate 102 may include channels or grooves for resin flow in the composite fabrication process. Such features may enhance the quality and consistency of the produced composites.
The design of the bottom plate 102 may contribute significantly to the overall functionality of the mould assembly 100, providing a stable and versatile foundation for the fabrication of functionally graded hybrid fiber reinforced polymer composites.
FIG. 1C illustrates a top view of a top plate 104 of the mould assembly 100 of FIG. 1A, according to aspects of the present disclosure.
The top plate 104 may be designed as a square-shaped component with several key features. Around the perimeter of the top plate 104, a plurality of connection holes 116 may be arranged. These connection holes 116 may include a first connection hole 116a and an nth connection hole 116n, indicating multiple holes positioned strategically around the edge of the plate. The connection holes 116 may be utilized for securing the top plate 104 to the bottom plate 102 of the mould assembly 100.
In the center of the top plate 104, a handle 118 may be incorporated. The handle 118 may be depicted as a straight line, suggesting it may be a bar or rod-like structure attached to the surface of the top plate 104. The handle 118 may provide a means for lifting or manipulating the top plate 104 during the mould assembly process or when removing the finished composite product.
The arrangement of the connection holes 116 around the perimeter and the centrally located handle 118 may allow for even distribution of pressure when the mould assembly 100 is assembled. Such configuration may facilitate easy handling of the top plate 104 and ensure uniform compression of the composite layers during the curing process.
In some aspects of the present disclosure, the top plate 104 may be fabricated from materials with specific thermal properties to ensure efficient heat transfer during the curing process. For example, the top plate 104 may be made from materials with high thermal conductivity to promote even heating of the composite.
The surface of the top plate 104 that comes into contact with the composite may be treated or coated to prevent adhesion of the cured composite. This treatment may include the application of release agents or the use of non-stick coatings, facilitating easy removal of the finished composite product.
In some aspects of the present disclosure, the top plate 104 may incorporate additional features to enhance the composite fabrication process. For instance, the top plate 104 may include integrated heating elements to provide localized or uniform heating during the curing process. Alternatively, the top plate 104 may be designed with channels or grooves to accommodate temperature sensors or thermocouples for precise temperature monitoring during curing.
The thickness and rigidity of the top plate 104 may be optimized to withstand the pressures applied during the composite fabrication process while maintaining a uniform surface. Such design consideration may help ensure the production of composites with consistent thickness and surface quality.
In some aspects of the present disclosure, the top plate 104 may be interchangeable with other top plates of different configurations. The modularity may allow for the fabrication of composites with varying surface textures or patterns by simply swapping the top plate 104.
The design of the top plate 104 may contribute significantly to the overall functionality of the mould assembly 100, working in conjunction with the bottom plate 102 to create a controlled environment for the fabrication of functionally graded hybrid fiber reinforced polymer composites.
FIG. 1D illustrates an isometric view of a partial assembly 126 of a mould for fabricating functionally graded hybrid fiber reinforced polymer composites, according to aspects of the present disclosure.
The partial assembly 126 may comprise a bottom plate 102, a first supporting fixture 110, and a second supporting fixture 112. The bottom plate 102 may form the base of the assembly and may feature multiple holes arranged in a pattern across the surface. The holes may serve various purposes such as alignment, fastening, or material flow during the composite fabrication process.
The first supporting fixture 110 and second supporting fixture 112 may be positioned on opposite sides of the bottom plate 102. The supporting fixtures may be elongated structures that extend vertically from the bottom plate 102. Each supporting fixture may have a groove or channel running along the length, which may be used to accommodate sliding components or guide the placement of materials during the composite layup process.
In some aspects of the present disclosure, the supporting fixtures 110 and 112 may be adjustable in height relative to the bottom plate 102. The adjustability may be facilitated by a mechanism such as threaded rods or adjustable bolts, allowing for fine-tuning of the fixture height to accommodate different composite thicknesses or to create specific gradations in the composite structure.
The arrangement of the bottom plate 102 and the supporting fixtures 110 and 112 may create a framework that can support and constrain materials during the composite fabrication process. Such design may allow for adjustability and precision in positioning materials within the mould.
In some aspects of the present disclosure, the partial assembly 126 may include additional features not visible in the isometric view. For example, the supporting fixtures 110 and 112 may incorporate locking mechanisms to secure their position once adjusted. Furthermore, the surfaces of the supporting fixtures that come into contact with the composite materials may be treated or coated to prevent adhesion and facilitate easy release of the finished product.
The partial assembly 126 may be designed to accommodate various sizes and configurations of composite parts. In some aspects of the present disclosure, the supporting fixtures 110 and 112 may be interchangeable or modular, allowing for customization of the mould assembly 100 to suit specific composite fabrication requirements.
The design of the partial assembly 126 may contribute significantly to the overall functionality of the mould assembly 100, providing a stable and adjustable framework for the precise layup of functionally graded hybrid fiber reinforced polymer composites. Such configuration may enable the creation of composites with tailored properties along their thickness, offering advantages in terms of strength, stiffness, and functionality for various industrial applications.
FIG. 1E illustrates an orthogonal view of the partial assembly 126 of the mould assembly 100 of FIG. 1A, according to aspects of the present disclosure.
The partial assembly 126 may comprise the bottom plate 102, the first supporting fixture 110, and the second supporting fixture 112. The first supporting fixture 110 and second supporting fixture 112 may be attached to opposite sides of the bottom plate 102 using nuts and bolts 122.
The first supporting fixture 110 may include a first groove for slider 114a, while the second supporting fixture 112 may include a second groove for slider 114b. The grooves may be designed to accommodate the first slider 106 and the second slider 108 (not shown in this figure), which can move horizontally along the length of the supporting fixtures.
In some aspects of the present disclosure, the grooves 114a and 114b may be precision-machined to ensure smooth and accurate movement of the sliders. The grooves may be designed with specific dimensions to match the cross-section of the sliders, providing a secure fit while allowing for easy movement.
The nuts and bolts 122 securing the supporting fixtures to the bottom plate 102 may allow for adjustable height positioning of the fixtures. Such feature may enable the mould assembly 100 to accommodate composites of varying thicknesses and facilitate the creation of functionally graded structures along the thickness of the composite.
In some aspects of the present disclosure, the supporting fixtures 110 and 112 may be fabricated from materials with high stiffness and dimensional stability to maintain precise alignment during the composite fabrication process. Materials such as tool steel or high-strength aluminum alloys may be used for this purpose.
The orthogonal view presented in FIG. 1E may provide a clear perspective on the alignment and positioning of the supporting fixtures relative to the bottom plate 102. This view may be particularly useful for understanding the spatial relationships between components and for planning the composite layup process.
In some aspects of the present disclosure, the partial assembly 126 may include additional features not visible in the orthogonal view. For example, the bottom plate 102 may incorporate channels or reservoirs for excess resin collection, or the supporting fixtures may include integrated clamping mechanisms for securing fiber materials during layup.
The design of the partial assembly 126, as shown in FIG. 1E, may allow for precise control over the fiber placement and gradation process. The combination of adjustable supporting fixtures and horizontally movable sliders may enable the creation of complex fiber architectures within the composite structure, facilitating the production of functionally graded materials with tailored properties along their thickness.
FIG. 1F illustrates an orthogonal view of a partial assembly 128 of the mould assembly 100 of FIG. 1A, according to aspects of the present disclosure.
The partial assembly 128 may comprise the first supporting fixture 110 and the second supporting fixture 112, positioned parallel to each other. The supporting fixtures may be connected to a base plate (not visible in this view) via nuts and bolts.
The first slider 106 may be attached to the first supporting fixture 110, while the second slider 108 may be attached to the second supporting fixture 112. Both sliders may be positioned horizontally along the length of their respective supporting fixtures. The sliders 106 and 108 may be designed to move along the supporting fixtures, allowing for adjustable positioning during the composite fabrication process.
In some aspects of the present disclosure, the supporting fixtures 110 and 112 may have a rectangular cross-section and may be elevated above the base plate by short vertical supports at each end. The supports may be secured to the base plate using nuts and bolts, providing stability to the entire assembly.
The sliders 106 and 108 may be elongated rectangular bars that fit into grooves on the top surface of the supporting fixtures. Such design may allow the sliders to move smoothly along the length of the supporting fixtures while maintaining their alignment.
In some aspects of the present disclosure, the partial assembly 128 may include locking mechanisms to secure the sliders in place once positioned. The mechanisms may allow for precise control over the width of different fiber zones within each composite layer.
The design of the partial assembly 128 may facilitate the creation of distinct zones within each layer of the composite, allowing for the gradual transition of material properties across the thickness of the final product. Suchconfiguration may be particularly useful for creating functionally graded composites with tailored mechanical or thermal properties.
In some aspects of the present disclosure, the surfaces of the sliders 106 and 108 that come into contact with the composite materials may be treated or coated to prevent adhesion and facilitate easy release of the finished product. Such treatment may help maintain the integrity of the composite layers during the fabrication process.
The partial assembly 128 may be designed to accommodate various widths of composite parts. In some aspects of the present disclosure, the sliders 106 and 108 may be interchangeable or adjustable in length, allowing for customization of the mould assembly 100 to suit specific composite fabrication requirements.
Such configuration of supporting fixtures and sliders may enable precise control over fiber placement and orientation, potentially allowing for the creation of complex composite structures with optimized mechanical properties in specific directions or regions.
FIG. 1G illustrates orthogonal views of the partial assembly 128 of the mould assembly 100 of FIG. 1A, according to aspects of the present disclosure. The figure shows two views: a side view and an end view of the assembly.
The partial assembly 128 may comprise a bottom plate 102, which serves as the base for the mould. Positioned above the bottom plate 102 may be two sliders: a first slider 106 and a second slider 108. The sliders may be arranged parallel to each other and extend across the length of the bottom plate 102.
The sliders 106 and 108 may be secured to the bottom plate 102 using nuts and bolts 122. The fasteners may be visible at both ends of the sliders in the side view, and in cross-section in the end view. The nuts and bolts 122 may allow for adjustable positioning of the sliders relative to the bottom plate 102. The first slider 106 and second slider 108 are flat steel plates, wherein the ends of the first slider 106 and second slider 108 are attached with the nuts 122, wherein the nuts 122 are passing through the grooves 114 of the supporting fixtures 110 and 112, wherein the first slider 106 and second slider 108 moves freely on either ways by adjusting the bolts on 122
In some aspects of the present disclosure, the height of the sliders 106 and 108 relative to the bottom plate 102 may be adjustable. Such feature may allow for the creation of composite layers with varying thicknesses or for accommodating different fiber types within the same layer.
The arrangement of the components in the partial assembly 128 may allow for adjustable spacing between the sliders, which can be used to control the placement and width of different materials during the composite fabrication process. The adjustability may be crucial for creating functionally graded zones within each layer of the composite.
In some aspects of the present disclosure, the bottom plate 102 may include additional features not visible in these views, such as alignment markers or recesses to assist in precise positioning of the sliders and other components.
The end view may provide insight into the cross-sectional profile of the sliders 106 and 108. In some aspects, these sliders may have specially designed profiles to facilitate fiber placement or to create specific fiber orientations within the composite layers.
The partial assembly 128, as shown in FIG. 1G, may demonstrate the modular nature of the mould assembly 100. This design may allow for easy disassembly, cleaning, and maintenance of the mould components, which could be beneficial for long-term use in composite manufacturing processes.
In some aspects of the present disclosure, the materials used for the bottom plate 102 and sliders 106 and 108 may be selected for their thermal properties, ensuring uniform heat distribution during the curing process of the composite materials.
This configuration may enable the fabrication of complex functionally graded hybrid fiber reinforced polymer composites with precise control over fiber placement, orientation, and gradation across the thickness of the composite structure.
FIG. 1H illustrates a method 130 for fabricating a functionally graded hybrid fiber reinforced polymer composite using a mould assembly 100, according to aspects of the present disclosure. The method 130 comprises nine steps, each represented by a separate image.
The first step 132 may involve placing a thin plastic film over the bottom plate 102 of the mould assembly 100. This film may serve as a release layer, preventing the composite from adhering to the mould surface.
In the second step 134, a first layer of fiber may be positioned on the plastic film, and epoxy may be applied. This step may establish the base layer of the composite structure.
The third step 136 may depict the adjustment of the mould's sliders to prepare for the next layer. This adjustment may allow for the creation of distinct zones in the subsequent layer.
The fourth step 138 may show the placement of different fiber types for the second layer, with the sliders positioned to create distinct zones. This step may begin the functional gradation process.
In the fifth step 140, the sliders may be adjusted again, and a third layer of fibers may be added to continue the functional gradation. This step may further develop the graded structure of the composite.
The sixth step 142 may illustrate the addition of the final fiber layer to complete the composite stack. This step may finalize the layup process of the composite.
The seventh step 144 may show the top plate 104 of the mould assembly 100 being placed over the stacked composite layers. This step may prepare the composite for the curing process.
In the eighth step 146, the assembled mould may be cured in an oven. This step may allow the epoxy to set and bond the composite layers together.
The ninth step 148 may show the final fabricated composite after removal from the mould assembly 100.
The adjustment of sliders in steps 136 and 140 may be precisely controlled using measurement tools or pre-set stops to ensure consistent gradation across multiple composite parts.
In some aspects, the epoxy application in steps 134, 138, and 140 may be performed using specialized equipment to control resin content and ensure even distribution throughout the fiber layers.
The curing process in step 146 may be customized with specific temperature profiles and durations to optimize the properties of the functionally graded composite. In some cases, this may involve a multi-stage curing process with varying temperatures.
The method 130 may demonstrate a systematic approach to creating functionally graded hybrid composites, utilizing the adjustable features of the mould assembly 100 to control fiber placement and achieve gradation across the composite layers. This process may enable the production of composites with tailored properties for specific applications in aerospace, automotive, or other industries requiring advanced materials.
In some aspects of the present disclosure, epoxy may be applied to each layer of fibers after placement. This step ensures proper impregnation of the fibers and helps maintain the desired fiber orientation within each layer.
The curing process in step 146 may be conducted at a temperature of 80°C for three hours. This specific curing profile may be optimized to achieve the desired mechanical properties of the functionally graded hybrid composite.
After curing and before removal from the mould assembly 100, the composite may be allowed to cool. This controlled cooling process may help prevent warping or internal stresses in the final composite product.
FIG. 2 illustrates a flowchart of a method 200 for fabricating a functionally graded hybrid fiber reinforced polymer composite using a mould assembly 100, according to aspects of the present disclosure. The method 200 comprises a series of sequential steps for the composite fabrication process.
The method 200 may begin with step 202, where a thin plastic film is placed over the bottom plate 102 of the mould assembly 100. This step may prepare the surface for the composite layup and prevent adhesion of the composite to the mould.
In step 204, a first layer of fiber may be positioned on the plastic film, and epoxy may be applied. This step may establish the base layer of the composite structure.
Step 206 may involve adjusting the first and second sliders of the mould assembly 100 to prepare for a subsequent layer. This adjustment may allow for the creation of distinct zones in the next layer, facilitating the functional gradation process.
Step 208 may describe the placement of different fiber types for the second layer, with the sliders positioned to create distinct zones. This step may begin the functional gradation process, allowing for the incorporation of varying material properties within the same layer.
In step 210, the sliders may be adjusted again, and a third layer of fibers may be added to continue the functional gradation. This step may further develop the graded structure of the composite, potentially decreasing the width of one fiber type while increasing the other.
Step 212 may involve adding a final fiber layer to complete the composite stack. This step may finalize the layup process of the composite, potentially using a single fiber type for the outermost layer.
Step 214 may describe placing the top plate 104 of the mould assembly 100 over the stacked composite layers. This step may prepare the composite for the curing process and ensure even pressure distribution across the layup.
In step 216, the assembled mould may be cured in an oven. This step may allow the epoxy to set and bond the composite layers together. In some aspects, the curing process may be conducted at a temperature of 80°C for three hours.
The final step 218 may involve removing the fabricated composite from the mould assembly 100. This step may complete the fabrication process, resulting in the finished functionally graded hybrid composite.
In some aspects of the present disclosure, additional steps may be incorporated into the method 200. For example, a step for applying release agent to the mould surfaces may be included before placing the plastic film. This may further ensure easy removal of the cured composite.
The method 200 may also include steps for quality control, such as visual inspections or non-destructive testing between layers or after curing. These steps may help ensure the integrity of the functional gradation and overall composite quality.
In some aspects, the method 200 may incorporate a cooling step after curing and before removal from the mould. This controlled cooling may help prevent warping or internal stresses in the final composite.
The method 200 outlines a systematic approach to creating functionally graded hybrid composites, utilizing adjustable sliders in the mould assembly 100 to control fiber placement and achieve gradation across the composite layers. This process may enable the production of composites with tailored properties for specific applications in various industries requiring advanced materials.
The mould assembly 100 used in method 200 may be adaptable for various composite fabrication techniques. In some aspects of the present disclosure, the mould assembly 100 may be modified for use, potentially incorporating inlets and outlets for resin transfer.
The method 200 may be applicable to a wide range of fiber types and configurations. The mould assembly 100 may enable the fabrication of composites with varying fiber types, including unidirectional, bidirectional, and chopped fibers. This versatility allows for the creation of functionally graded composites with tailored properties for specific applications.
In some aspects of the present disclosure, the mould assembly 100 may be scaled or modified to produce composite coupons for standardized testing, such as those conforming to ASTM or IS dimensions. This capability may facilitate quality control and material characterization processes in research and industrial settings.
Thus, the mould assembly 100 and the method 200 provide several technical advantages for fabricating functionally graded hybrid fiber reinforced polymer composites. The adjustable supporting fixtures and movable sliders enable precise control over fiber placement and gradation, allowing for the creation of distinct zones within each composite layer. This design facilitates the production of composites with tailored mechanical and thermal properties along their thickness. The versatility of the mould assembly 100 accommodates various fiber types and configurations, including unidirectional, bidirectional, and chopped fibers, expanding its applicability across different composite manufacturing requirements. The modular nature of the assembly allows for easy disassembly, cleaning, and maintenance, enhancing its long-term usability in industrial settings. Furthermore, the mould assembly 100 can be scaled or modified to produce standardized test coupons, facilitating quality control and material characterization processes. The method's systematic approach, incorporating controlled fiber placement, epoxy application, and curing, ensures consistent production of high-quality functionally graded composites suitable for advanced applications in aerospace, automotive, and other industries requiring specialized materials.

Aspects of the present disclosure are discussed here with reference to flowchart illustrations and block diagrams that depict methods, systems, and apparatus in accordance with various aspects of the present disclosure. The flowcharts and block diagrams presented in the figures depict the architecture, functionality, and operation of potential implementations of systems, methods, and apparatus according to different aspects of the present disclosure.
Although the preferred aspects have been detailed here, it should be apparent to those skilled in the relevant field that various modifications, additions, and substitutions can be made without departing from the scope of the disclosure. These variations are thus considered to be within the scope of the disclosure as defined in the following claims.
Features or functionalities described in certain example aspects may be combined and re-combined in or with other example aspects. Additionally, different aspects and elements of the disclosed example aspects may be similarly combined and re-combined. Further, some example aspects, individually or collectively, may form components of a larger system where other processes may take precedence or modify their application. Moreover, certain steps may be required before, after, or concurrently with the example aspects disclosed herein. It should be noted that any and all methods and processes disclosed herein can be performed in whole or in part by one or more entities or actors in any manner.
Although terms like "first," "second," etc., are used to describe various elements, components, regions, layers, and sections, these terms should not necessarily be interpreted as limiting. They are used solely to distinguish one element, component, region, layer, or section from another. For example, a "first" element discussed here could be referred to as a "second" element without departing from the teachings of the present disclosure.
The terminology used here is intended to describe specific example aspects and should not be considered as limiting the disclosure. The singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "includes," "comprising," and "including," as used herein, indicate the presence of stated features, steps, elements, or components, but do not exclude the presence or addition of other features, steps, elements, or components.
As used herein, the term "or" is intended to be inclusive, meaning that "X employs A or B" would be satisfied by X employing A, B, or both A and B. Unless specified otherwise or clearly understood from the context, this inclusive meaning applies to the term "or."
Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the relevant art. Terms should be interpreted consistently with their common usage in the context of the relevant art and should not be construed in an idealized or overly formal sense unless expressly defined here.
The terms "about" and "substantially," as used herein, refer to a variation of plus or minus 10% from the nominal value. This variation is always included in any given measure.
In cases where other disclosures are incorporated by reference and there is a conflict with the present disclosure, the present disclosure takes precedence to the extent of the conflict, or to provide a broader disclosure or definition of terms. If two disclosures conflict, the later-dated disclosure will take precedence.
The use of examples or exemplary language (such as "for example") is intended to illustrate aspects of the invention and should not be seen as limiting the scope unless otherwise claimed. No language in the specification should be interpreted as implying that any non-claimed element is essential to the practice of the invention.
While many alterations and modifications of the present invention will likely become apparent to those skilled in the art after reading this description, the specific aspects shown and described by way of illustration are not intended to be limiting in any way.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Acknowledgement
It is acknowledged the research around the present invention has been funded by CSIR New Delhi, under Sanction Order No. 22(0781)/19/EMR-II. We are grateful for their support in enabling this invention.
, Claims:1. A mould assembly (100) for fabricating functionally graded hybrid fiber reinforced polymer composites, comprising:
a bottom plate (102);
a top plate (104) configured to cover the bottom plate;
a first supporting fixture (110) and a second supporting fixture (112) attached to opposite sides of the bottom plate;
a first slider (106) and a second slider (108) movably connected to the first supporting fixture and the second supporting fixture, respectively;
wherein the first supporting fixture and the second supporting fixture each comprise a groove (114) for accommodating the respective slider, wherein the first slider (106) and second slider (108) are flat steel plates, wherein the ends of the first slider (106) and second slider (108) are attached with the nuts(122), wherein the nuts (122) are passing through the grooves (114) of the supporting fixtures (110) and (112), wherein the first slider (106) and second slider (108) moves freely on either ways by adjusting the bolts on (122); and
wherein the first slider and the second slider are configured to move horizontally along the grooves to facilitate functional gradation of fibers during composite fabrication.
2. The mould assembly (100) as claimed in claim 1, wherein the first supporting fixture (110) and the second supporting fixture (112) are vertically adjustable relative to the bottom plate (102).
3. The mould assembly (100) as claimed in claim 2, wherein the vertical adjustment of the first supporting fixture (110) and the second supporting fixture (112) is facilitated by nuts and bolts (122) connecting the supporting fixtures to the bottom plate (102).
4. The mould assembly (100) as claimed in claim 1, wherein the bottom plate (102) comprises a plurality of holders (120) for lifting and maneuvering the bottom plate, and wherein the top plate (104) comprises a handle (118) for lifting and positioning the top plate.
5. The mould assembly (100) as claimed in claim 1, wherein the bottom plate (102) and the top plate (104) comprise a plurality of connection holes (116) for securing the top plate to the bottom plate.
6. The mould assembly (100) as claimed in claim 5, wherein the connection holes (116) are arranged around a perimeter of the bottom plate (102) and the top plate (104) to allow for even distribution of pressure when the mould assembly is assembled.
7. A method (200) for fabricating a functionally graded hybrid fiber reinforced polymer composite using a mould assembly (100), the method comprising:
placing a thin plastic film over a bottom plate (102) of the mould assembly;
positioning a first layer of fiber on the plastic film and applying epoxy;
adjusting a first slider (106) and a second slider (108) of the mould assembly to prepare for a subsequent layer;
placing different fiber types for a second layer, with the sliders positioned to create distinct zones;
adjusting the sliders again and adding a third layer of fibers to continue functional gradation;
adding a final fiber layer to complete a composite stack;
placing a top plate (104) of the mould assembly over the stacked composite layers;
curing the assembled mould in an oven; and
removing the fabricated composite from the mould assembly.
8. The method (200) as claimed in claim7, wherein adjusting the first slider (106) and the second slider (108) comprises vertically adjusting supporting fixtures (110, 112) to which the sliders are attached, wherein vertically adjusting the supporting fixtures (110, 112) is facilitated by nuts and bolts (122) connecting the supporting fixtures to the bottom plate (102), and wherein placing different fiber types for the second layer comprises positioning a first fiber type between the first slider (106) and the second slider (108), and positioning a second fiber type in gaps between the sliders and edges of the bottom plate (102).
9. The method (200) as claimed in claim 8, wherein adjusting the sliders again for the third layer comprises decreasing a distance between the first slider (106) and the second slider (108) to create a narrower zone for the first fiber type, and wherein curing the assembled mould comprises heating the mould assembly (100) in an oven at a temperature of 80°C for three hours.
10. The method (200) as claimed in claim 7, further comprising applying epoxy to each layer of fibers after placement; and allowing the cured composite to cool before removing it from the mould assembly (100).

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