Co-curing Reinforced Panel Components to Reduce Cycle Time
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for joining stringers to skin panels in aircraft are time-consuming and costly, requiring multiple processing cycles, which increases part counts and weight.
Innovation Solution
A method and apparatus for forming reinforced panel components by simultaneously applying heat and pressure to co-bond the faying surfaces of reinforcement and panel components, reducing cycle times and costs while minimizing part counts and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-cycle processing methods are used to join stringers to skin panels, then bonding strength and structural integrity are achieved, but cycle time and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple separate processing cycles (surface preparation, bonding, curing) into a single integrated autoclave cycle. The skin panel and stringer are co-cured together in one continuous process, eliminating the need for separate surface treatment and bonding steps that were required in traditional multi-cycle methods.
Solution Approach 2:
The skin panel is prepared in advance with a surface layer containing reactive groups (epoxy, carboxyl, hydroxyl, or amine groups) that are pre-configured to bond with the stringer material. This preliminary surface preparation with built-in bonding capability allows the subsequent co-curing process to proceed without additional surface treatment steps.
2Reliability
If traditional multi-cycle processing methods are used to join stringers to skin panels, then adequate bonding is achieved, but manufacturing cost increases due to extended processing time
Solution Approach 1:
The patent merges multiple discrete manufacturing operations into a single autoclave co-curing cycle, reducing the total number of process steps, handling operations, and quality inspection points required. This integration directly reduces manufacturing complexity and associated costs.
Solution Approach 2:
The co-curing process maintains continuous heating and pressing throughout the entire bonding operation, eliminating the idle time and temperature cycling associated with traditional multi-step processes. The useful action of bonding continues uninterrupted from start to finish of the single autoclave cycle.
3Reliability
If multiple processing cycles are used for joining reinforcement components, then bonding reliability is maintained, but part count and weight increase
Solution Approach 1:
The patent combines the skin panel and stringer into a single integrated structural component through co-curing, reducing the effective part count. The bonded interface becomes an integral part of the structure rather than a separate assembly, eliminating the need for additional fasteners, adhesives, or intermediate components.
4Reliability
If traditional joining methods are used, then structural integrity is achieved, but production efficiency decreases
Solution Approach 1:
The skin panel surface is pre-prepared with reactive bonding groups that are stable during storage but activate during co-curing. This preliminary configuration of bonding capability allows rapid production without compromising the integrity that would require traditional multi-step surface treatments and quality checks.
Solution Approach 2:
The single autoclave co-curing cycle maintains continuous bonding action throughout the entire process, maximizing production efficiency by eliminating the idle time and repeated heating/cooling cycles inherent in traditional multi-step joining methods while ensuring complete structural integrity.
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 significantly reduces cycle times from 8-10 hours to 20-50 minutes, lowering costs and maintaining minimal part counts and weight, thus enhancing efficiency and reducing operational expenses.
Implementation Method 1
heating the first and second portions of the press to a curing temperature associated with the panel component to simultaneously or substantially simultaneously co-bond the faying surfaces of the reinforcement component and the panel component together
Implementation Method 2
actuating the press to direct the first and second portions of the press toward each other, such that the faying surfaces of the reinforcement component and the panel component are complementarily engaged under pressure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of forming a reinforced panel may include engaging a reinforcement component having a faying surface with a first portion of a heated press, engaging an uncured panel component with an opposing second portion of the press, the panel component having a faying surface complementarily-configured with respect to the faying surface of the reinforcement component, treating the faying surface of the reinforcement component such that the faying surface is active for co-bonding with respect to the panel component, actuating the press to direct the first and second portions of the press toward each other, such that the faying surfaces are complementarily engaged under pressure; and heating the first and second portions of the press to a curing temperature associated with the panel component to simultaneously or substantially simultaneously co-bond the faying surfaces of the reinforcement component and the panel component together, cure the panel component, and form the reinforced panel.