Baffle Layers and Spacers for Composite Flow Control

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Solution Overview

Problem

The infusion of materials into composite laminates for vehicle components often results in undersaturation or oversaturation due to uneven material distribution, leading to limited reinforcement and structural integrity issues.

Innovation Solution

A system utilizing baffle layers and spacers, generated through computational analysis and 3D printing, is used to control the flow of materials within vehicle components, creating specific flow paths to ensure uniform distribution and reduce dry spots and oversaturation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If materials are infused into composite laminate, then reinforcement is added, but uneven distribution causes undersaturation and oversaturation

Engineering Contradiction:

ImprovereinforcementVSAvoidmaterial distribution uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The flow medium is segmented into multiple baffle layers with different permeability zones, dividing the infusion process into controlled segments that direct material flow to specific areas of the composite laminate, preventing both undersaturation and oversaturation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the flow medium are assigned different local qualities through varying permeability characteristics of baffle layers. Areas requiring more material have higher permeability zones, while areas needing less material have lower permeability zones, achieving uniform distribution

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If flow medium is used to control material distribution, then uniform infusion is achieved, but device complexity increases

Engineering Contradiction:

Improvematerial distribution uniformityVSAvoidflow medium structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The flow medium serves multiple functions simultaneously: it distributes material uniformly, supports the composite laminate layers, defines flow paths, and controls infusion pressure. This multi-functionality reduces the need for separate components, offsetting the complexity with functional integration

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Multiple baffle layers are nested within the flow medium structure, with each layer contained within the overall flow medium boundary. This nested arrangement allows complex functionality to be achieved through hierarchical organization rather than separate external components

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS11642858B2Systems, methods, and apparatus for flow media associated with the manufacture of components

Publication Date: 2023.05.09 THE BOEING CO

AI summary

Systems, methods, and apparatus are disclosed for controlling a flow of a material through a vehicle component. In some embodiments, the methods include determining a first plurality of dimensions and a second plurality of dimensions associated with a flow medium based on one or more flow properties of the vehicle component, the flow medium including a plurality of baffle layers and a plurality of spacers. The methods may further include generating at least one baffle layer based on the first plurality of dimensions, and generating at least some of the plurality of spacers based on the second plurality of dimensions, the plurality of spacers being positioned on top of the at least one baffle layer.