Continuous CFRP Curved Frame Mold via Segmented Tooling
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Solution Overview
Problem
Current methods for continuous molding of carbon fiber reinforced polymer (CFRP) components are limited in creating curved shapes like fuselage frames, often requiring multiple parts and joints, which increase weight and assembly costs, and are challenging due to geometry clashes with mold tools.
Innovation Solution
A method and apparatus for continuously molding CFRP slender components by introducing out-of-plane curvature using a forming tool with a 'corkscrew' or 'pigtail' design, either through mold geometry or mechanical deflection, allowing for curved shapes without clashing with tooling, and optionally including a heating and re-curing process to eliminate curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional continuous molding methods are used for CFRP components, then straight and constant section parts can be manufactured efficiently, but curved and variable geometry parts like fuselage frames cannot be produced without multiple joints
Solution Approach 1:
The mold tooling is divided into multiple segments that can independently move relative to each other. This segmentation allows the mold to accommodate curved and variable geometry parts without requiring a completely complex monolithic tooling system, as each segment can be positioned to match the specific geometry being formed.
Solution Approach 2:
The mold tooling transitions from a static configuration to a dynamic one where segments can move and adjust during the molding process. This dynamic capability enables the formation of curved geometries by allowing the mold segments to follow the contours of the desired part shape while maintaining continuous molding capability.
2Productivity
If fuselage frames are cut into multiple parts to avoid geometry clashes with mold tooling, then continuous molding is compromised, but weight and assembly costs increase due to additional joints
Solution Approach 1:
The mold tooling is segmented to navigate around geometric complexities during the molding process, allowing the continuous mold to follow the curvature of fuselage frames without stopping or cutting the material flow, thus maintaining continuous production capability.
Solution Approach 2:
The mold segments are pre-positioned and configured to anticipate and accommodate the curvature of the fuselage frame geometry before the CFRP material is laid up, preventing geometry clashes during the molding process and enabling continuous production of curved parts.
3Adaptability or versatility
If more joints are used to create curved shapes, then manufacturing flexibility is improved, but weight and assembly complexity increase
Solution Approach 1:
The dynamic mold segments provide manufacturing flexibility by allowing the tooling to adapt to curved geometries during the molding process itself, eliminating the need for multiple joints and subsequent assembly operations, thereby reducing assembly complexity.
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
Enables the creation of continuously molded CFRP fuselage frames with reduced weight and complexity by avoiding the need for multiple joints and allowing for full 360-degree curvature, while maintaining structural integrity and flexibility.
Implementation Method 1
curing the carbon fiber reinforced polymer material into a component of the desired shape in the forming tool
Implementation Method 2
a further heating and re-curing process to eliminate the out-of-plane curvature after the component has been cut
Data Source
AI summary
A method and apparatus for forming a continuously molded carbon fiber reinforced polymer slender curved frame. A continuous supply of uncured carbon fiber reinforced polymer material is directed into a forming tool. The uncured carbon fiber reinforced polymer material is continuously molded into a desired shape in the forming tool. The carbon fiber reinforced polymer material is cured into a frame of the desired shape in the forming tool. The frame is removed from the forming tool. An out-of-plane curvature is put in the frame while the frame is in at least a portion of the forming tool.