Cleaning Ceramic Matrix from Compaction Roller

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Solution Overview

Problem

The manual compaction of ceramic matrix composite plies results in variable quality and inconsistencies, and remnants of the ceramic matrix composite plies often remain on the surface of compaction rollers, requiring effective cleaning methods to prepare for subsequent operations.

Innovation Solution

A method and system for cleaning a ceramic matrix from a compaction roller, involving the application of a cleaning fluid to a scrubbing roller, placing the compaction roller in contact with the scrubbing roller at an oblique angle, and rotating both rollers to transfer the cleaning fluid and debris from the compaction roller to the scrubbing roller, followed by drying to remove the cleaning fluid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual compaction operations are used, then skilled technicians can perform the compaction, but the process is time intensive and results in variable quality

Engineering Contradiction:

Improvecompaction quality consistencyVSAvoidcompaction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical compaction operations with an automated roller system that applies consistent pressure through controlled rotation and weight, eliminating variability introduced by manual techniques while maintaining effective compaction force

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention transforms the compaction process from manual variable pressure application to controlled parameter-based pressure application through roller weight, rotation speed, and contact pressure, ensuring consistent compaction quality across different operations

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If specialized compaction rollers are used, then compaction quality is improved, but debris remains on the roller surface requiring cleaning

Engineering Contradiction:

Improvecompaction qualityVSAvoidroller surface debris

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a cleaning roller as an intermediary element that contacts the compaction roller surface to remove debris, acting as a mediator between the compaction process and the roller maintenance requirement

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention implements a system where debris is continuously removed from the compaction roller surface through the cleaning roller mechanism, discarding the harmful contaminants while preserving the compaction roller's functional surface

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If cleaning operations are performed to remove debris, then roller surface is prepared for subsequent operations, but additional time is required

Engineering Contradiction:

Improveroller surface cleanlinessVSAvoidcleaning time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent makes the cleaning action continuous by positioning the cleaning roller to contact the compaction roller throughout its rotation, ensuring debris is removed continuously rather than requiring separate discrete cleaning operations

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The invention merges the compaction and cleaning functions into a single integrated system where the compaction roller performs both compaction and presents its surface to the cleaning roller, combining two operations that would traditionally be separate

Inventive Principle:

Principle #5Merging (Combining)

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 efficiently removes ceramic matrix debris from the compaction roller, ensuring consistent quality and reducing the need for rework and inspection, thereby improving the efficiency and reliability of ceramic matrix composite manufacturing.

Implementation Method 1

rotating the scrubbing roller about the scrubbing-roller axis... transferring debris from the compaction roller to the scrubbing roller

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

transferring the cleaning fluid from the scrubbing roller to the compaction roller... transferring debris from the compaction roller to the scrubbing roller

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

drying the compaction roller to remove the cleaning fluid from the compaction-roller surface

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 4

drying the compaction roller to remove the cleaning fluid from the compaction-roller surface

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentEP4563249A1Systems and methods for cleaning ceramic matrix from a compaction roller

Publication Date: 2025.06.04 THE BOEING CO

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AI summary

A method (1000) for cleaning a ceramic matrix (206) from a compaction roller (102) includes steps of: (1) applying a cleaning fluid (134) to the compaction roller (102) ; (2) scrubbing the compaction roller (102) to remove ceramic particles (166) of the ceramic matrix (206) from a compaction-roller surface of the compaction roller (102); and (3) drying the compaction roller (102) to remove the cleaning fluid (134) from the compaction-roller surface (102).