Autoclave Inner Surface Matching Preform Contours

Solution Overview

Problem

Large-scale autoclaves used for processing composite materials like Carbon Fiber Reinforced Polymer (CFRP) are energy-intensive, costly, and hinder efficient manufacturing due to their large thermal mass and varied geometry requirements, leading to increased utility costs and inefficient processing times.

Innovation Solution

The development of autoclaves with inner surfaces that match the contours of specific preforms, allowing for more precise heating and pressure application, reducing the volume and mass heated, and enabling continuous processing with Autonomous Guided Vehicles (AGVs) for efficient assembly line flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If large scale autoclaves are used to accommodate a wide range of component geometries, then versatility is improved, but energy consumption increases

Engineering Contradiction:

Improveaccommodation of component geometriesVSAvoidenergy consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The system divides the autoclave operation into separate dedicated units, each optimized for specific component types (e.g., fuselage autoclave, wing autoclave). This segmentation allows each autoclave to be smaller and more efficient while collectively providing versatile coverage for different component geometries through multiple specialized units operating in parallel or sequence.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If large scale autoclaves are used to accommodate a wide range of component geometries, then versatility is improved, but device complexity increases

Engineering Contradiction:

Improveaccommodation of component geometriesVSAvoidautoclave system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system divides the autoclave operation into separate dedicated units, each optimized for specific component types (e.g., fuselage autoclave, wing autoclave). This segmentation allows each autoclave to be smaller and more efficient while collectively providing versatile coverage for different component geometries through multiple specialized units operating in parallel or sequence.

Inventive Principle:

Principle #1Segmentation

3Productivity

If large scale autoclaves are used, then processing capacity is improved, but cycle time increases

Engineering Contradiction:

Improveprocessing capacityVSAvoidcycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system divides the autoclave operation into separate dedicated units, each optimized for specific component types. This allows multiple components to be processed simultaneously in different autoclaves, increasing overall throughput while each individual autoclave maintains shorter cycle times due to smaller thermal mass.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The autoclave is integrated into a continuous manufacturing line where preforms are continuously transported via AGVs from layup areas through processing stations into the autoclave. This continuous flow eliminates idle time between operations and maintains constant productive action, reducing overall cycle time while maintaining high processing capacity.

Inventive Principle:

Principle #20Continuity of useful action

4Productivity

If large scale autoclaves are used, then processing capacity is improved, but energy consumption increases

Engineering Contradiction:

Improveprocessing capacityVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system divides the autoclave operation into separate dedicated units, each optimized for specific component types. This allows multiple components to be processed simultaneously in different autoclaves, increasing overall throughput while each individual autoclave maintains shorter cycle times due to smaller thermal mass, thereby reducing total energy consumption.

Inventive Principle:

Principle #1Segmentation

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 reduces cycle time, energy consumption, and costs by optimizing heating efficiency, allowing for faster processing and improved factory operations with reduced equipment size and storage needs.

Implementation Method 1

autoclaves are heated by pumping heated gas into the autoclave at pressure

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

heated gas into the autoclave... heating the autoclave and its contents

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

pumping heated gas into the autoclave at pressure

Methodology Applied

Scientific EffectPressurisation: Pressurisation

Data Source

PatentUS11718046B2In-line autoclave adapted to preform geometry

Publication Date: 2023.08.08 THE BOEING CO

AI summary

A method for hardening a preform into a composite part is provided. The method comprises aligning a layup mandrel carrying a preform for insertion into an autoclave having an inner surface that is complementary to a contour of the preform. The layup mandrel is then sealed into the autoclave.