Boxed Thermoset Composite Stiffeners With Fewer Bonded Parts
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Solution Overview
Problem
The existing methods for stiffening structural parts made from thermoset composite materials, such as satellite antenna reflectors, are complex and time-consuming due to the need for numerous custom-made connecting parts and manual adhesive bonding at ambient temperature, which increases costs and reduces efficiency.
Innovation Solution
A method involving a first structure of hollow longitudinal bodies made from thermoset composite material, which can be adapted to complex forms through draping and impregnation with thermosetting resin, and a second structure, allowing for co-curing or co-bonding to create a stiffened part with reduced elements and simplified assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If numerous custom-made connecting parts and manual adhesive bonding are used to stiffen structural parts, then the parts achieve required dimensional stability and rigidity, but the manufacturing complexity and time consumption increase significantly
Solution Approach 1:
The shell is divided into multiple segments that can be assembled around a mandrel, with stiffening elements integrated into each segment. This segmentation allows the complex stiffening function to be distributed across multiple simpler components rather than requiring a single complex rigid structure.
Solution Approach 2:
The invention merges the shell structure with integrated stiffening elements into a single composite component. The stiffening elements are directly formed as part of the shell during the same manufacturing process, eliminating the need for separate connecting parts and subsequent assembly operations.
2Reliability
If numerous custom-made connecting parts and manual adhesive bonding operations are implemented, then reliable bonded connections are achieved, but the production time and manufacturing costs increase
Solution Approach 1:
The stiffening elements are pre-formed as integral parts of the shell segments during the molding process, before any assembly operations. The thermosetting resin is cured in place, creating permanently bonded, reliable connections without requiring subsequent manual adhesive bonding operations.
Solution Approach 2:
The invention replaces the mechanical assembly system (separate connecting parts requiring manual adhesive bonding) with a integrated molded structure. The chemical bonding of thermosetting resin during curing provides reliable connections, substituting the mechanical assembly process with a chemical bonding process that is both reliable and efficient.
3Adaptability or versatility
If many different connecting parts are used to adapt to variable bonding interfaces with different curvatures, then good contact with complex shell forms is achieved, but the number of elements and assembly operations increase
Solution Approach 1:
The shell segments are formed with integrated stiffening elements that can be molded in various curvatures to match different bonding interfaces. The thermosetting composite material allows the structure to be formed in complex shapes during molding, providing adaptability to variable interfaces without requiring multiple discrete connecting parts.
Solution Approach 2:
The integrated stiffening elements serve multiple functions: they provide structural rigidity, adapt to complex curved surfaces, and create bonding interfaces all in a single component. This multi-functional design eliminates the need for separate connecting parts that would otherwise be required to achieve each of these functions.
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 simplifies the stiffening process by reducing the number of elements and operations, enhances mechanical strength, and ensures reliable bonded connections while adapting to complex forms, thereby lowering manufacturing costs and improving efficiency.
Implementation Method 1
at least one body made from non-polymerised thermosetting composite material supported by a mandrel
Implementation Method 2
deposition of a non-polymerised thermosetting adhesive on a contact zone of an element to be bonded with another element of the part
Data Source
AI summary
A stiffened part formed from at least two members of thermoset composite material including at least one body of a first structure and optionally a second structure. A manufacturing method includes: forming a fibre preform and impregnating each body of the first structure with thermosetting resin or forming a pre-impregnated fibre preform to obtain a body formed from uncured thermosetting composite material supported by a mandrel; optionally partially or fully polymerising at least one body supported by a mandrel; optionally, providing the second structure formed from uncured, partially uncured or fully uncured thermosetting composite material; optionally, depositing a layer of uncured thermosetting adhesive on an area where a fully cured member makes contact with another member of the part; joining the members, each member being juxtaposed with; or stacked upon, at least one other member; fully curing the assembly by heat treatment; removing the mandrel from each fully cured body.