Aircraft Composite Lamination Using Flat and Wavy Prepreg Portions
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Solution Overview
Problem
The high cost and complexity of manufacturing fiber reinforced resin composite materials for aircraft parts due to the need for specialized auxiliary yarns and precise lamination of reinforcing fibers, which complicates the production process and increases costs.
Innovation Solution
A method of manufacturing an intermediate product for aircraft parts using a laminated body formed by prepregs with reinforcing fibers and resin, where a flat portion becomes the inner bent portion with a shorter circumference and a wavy portion becomes the outer bent portion, allowing for efficient production without the need for precise lamination or special reinforcing fiber base materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If auxiliary yarns are added to the reinforcing fiber base material to create curved shapes, then the fiber reinforced composite material can be formed in curved shapes, but the structure becomes complex and cost increases
Solution Approach 1:
The invention divides the fiber base material into two distinct components: a standard reinforcing fiber material and a separate curved shape defining element. This segmentation allows the reinforcing fibers to maintain their simple, cost-effective structure while the curved shape is defined by the separate element, resolving the contradiction between achieving curved shapes and maintaining structural simplicity.
Solution Approach 2:
The invention introduces a resin layer as an intermediary between the reinforcing fibers and the curved shape defining element. This resin layer acts as a mediator that bonds the standard reinforcing fibers to the curved shape defining element, enabling curved shape formation without requiring complex auxiliary yarns integrated into the fiber base material itself.
2Manufacturing precision
If precise lamination of prepregs is performed to achieve accurate curved shapes, then the quality and strength of aircraft parts are secured, but work efficiency decreases
Solution Approach 1:
The curved shape defining element is prepared in advance with the desired curved geometry, and the resin layer is applied beforehand. This preliminary preparation allows the reinforcing fibers to be laid up in a simple manner without requiring precise lamination operations during assembly, as the curved shape is already predetermined by the pre-prepared defining element.
Solution Approach 2:
The curved shape defining element serves as a self-aligning template that automatically guides the placement of reinforcing fibers and resin layers. This self-service mechanism eliminates the need for operators to perform complex precise lamination operations, thereby improving work efficiency while maintaining manufacturing precision.
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 method improves work efficiency and reduces production costs while maintaining the strength and quality required for aircraft parts with curved shapes, enabling the manufacture of aircraft parts with a curved structure and bent portions efficiently and economically.
Implementation Method 1
forming the intermediate product from the second laminated body by a forming die such that the flat portion becomes the bent portion that is an inside portion whose circumferential length is shorter in the curved portion, and the wavy portion becomes the bent portion that is an outside portion whose circumferential length is longer
Data Source
Figure 1
Figure 2
Figure 3A~3F
AI summary
A first laminated body is worked to form a second laminated body, the first laminated body being formed by laminating prepregs including reinforcing fibers and resin, the second laminated body including a flat portion and a wavy portion, the flat portion being located at at least one of side edge portions of the second laminated body, the wavy portion being located at a portion adjacent to the side edge portion and extending along a longitudinal direction. An intermediate product is formed from the second laminated body by a forming die such that the flat portion becomes a bent portion that is an inside portion whose circumferential length is shorter in a curved portion, and the wavy portion becomes a bent portion that is an outside portion whose circumferential length is longer in the curved portion.