Automated Bladder Preparation for Composite Stringer Manufacturing

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Solution Overview

Problem

Conventional methods for preparing bladders for composite stringer manufacturing are labor-intensive and time-consuming, involving manual application of breather layers, release films, and composite plies.

Innovation Solution

A system comprising a sock application station, a film application station, and a composite ply application station, which progressively applies a breather sock, inflates a film, and lays up composite plies over the bladder to form a ply-film-sock-bladder assembly, facilitating automated and efficient bladder preparation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual processes are used for applying breather layer, release film, and composite plies, then flexibility and simplicity are maintained, but labor intensity and time consumption increase

Engineering Contradiction:

Improveprocess simplicityVSAvoidpreparation speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The system divides the bladder preparation process into three distinct application stations: breather layer application, release film application, and composite ply application. Each station performs a specific function independently, allowing simultaneous operation and reducing overall preparation time while maintaining process clarity and control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces manual mechanical application processes with automated dispensing systems. Computer-controlled mechanisms precisely apply breather layers, release films, and composite plies without manual intervention, eliminating labor-intensive operations while maintaining or improving application precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If automated application systems are implemented, then productivity and consistency are improved, but device complexity increases

Engineering Contradiction:

Improvepreparation speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The application stations are designed as multi-functional units that can handle different materials (breather layers, release films, composite plies) using similar dispensing mechanisms. This universal design reduces overall system complexity compared to having separate specialized equipment for each material type, while maintaining high productivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system incorporates self-adjusting and self-regulating mechanisms that automatically optimize application parameters based on detected conditions. This reduces the need for complex control systems and manual intervention, simplifying operation while maintaining consistent high-speed application quality.

Inventive Principle:

Principle #25Self-service

3Device complexity

If manual application methods are used, then equipment investment is reduced, but labor costs and time requirements increase

Engineering Contradiction:

Improveequipment simplicityVSAvoidpreparation time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The system enables continuous application of breather layers, release films, and composite plies without interruption or repositioning. Materials are applied in a continuous stream as the bladder moves through the stations, eliminating idle time and significantly reducing total preparation time compared to batch-by-batch manual application.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system pre-positions and pre-prepares all application materials before the bladder arrives at each station. Breather layers, release films, and composite plies are staged and ready for immediate application, eliminating setup time during the preparation process and enabling continuous high-speed operation.

Inventive Principle:

Principle #10Preliminary action

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

The system automates the bladder preparation process, reducing labor and time while ensuring accurate application of layers, thereby enhancing the efficiency and consistency of composite stringer manufacturing.

Implementation Method 1

The film application station is configured to inflate a film from a flat shape into an open film tube prior to application over the sock-bladder assembly

Methodology Applied

Scientific EffectAir pressure inflation: Pressurisation

Data Source

PatentUS11724422B2Operator-assisted system and method for preparing a bladder for use in composite stringer manufacturing

Publication Date: 2023.08.15 THE BOEING CO

AI summary

A system for preparing a bladder for use in manufacturing a composite stringer includes a sock application station, a film application station, and a composite ply application station. The sock application station has a sock cartridge configured to progressively apply a breather sock of breather material in tubular form onto a bladder as the bladder exits the sock cartridge to thereby result in a sock-bladder assembly. The film application station is located downstream of the sock application station and is configured to inflate a film from a flat shape into an open film tube prior to application over the sock-bladder assembly to thereby result in a film-sock-bladder assembly. The composite ply application station is located downstream of the film application station and has a wrap ply forming bed containing at least one forming bed opening and configured to receive one or more wrap plies of a wrap laminate for urging into the forming bed opening by the film-sock-bladder assembly to produce a ply-film-sock-bladder assembly.