Composite Structure Processing With Compact Sealed Tooling
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Solution Overview
Problem
Conventional autoclave and oven processing techniques for large composite components, such as aircraft structures, are inefficient due to high space requirements, long cycle times, high costs, and manual labor, necessitating the development of more efficient processing methods.
Innovation Solution
A movable tooling assembly forms a sealed vessel with a mandrel-tool to apply pressure and heat directly to the composite structure, reducing the need for large equipment volumes and manual handling, and enabling faster processing cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but the equipment requires significant floor space and has large gas volume requirements
Solution Approach 1:
The patent divides the processing system into modular components: a mandrel tool that supports the composite structure and a separate tooling assembly that forms the pressure vessel. This segmentation allows the processing equipment to be more compact and reduces the overall floor space requirement compared to conventional autoclaves and ovens.
Solution Approach 2:
The tooling assembly nests around the mandrel tool to form a compact pressure vessel. The heating and pressurization systems are integrated within this nested configuration, minimizing the equipment footprint while maintaining processing capability.
2Reliability
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but the equipment requires huge volumes of heated gas
Solution Approach 1:
By segmenting the processing system into a mandrel tool and a compact tooling assembly, the volume of gas that needs to be heated and pressurized is dramatically reduced compared to conventional autoclaves and ovens, lowering energy consumption and equipment costs.
Solution Approach 2:
The tooling assembly acts as an intermediary pressure vessel that directly contacts the composite structure on the mandrel tool. This eliminates the need for huge volumes of heated gas required in conventional systems, as the pressure and heat are applied more efficiently through the sealed vessel configuration.
3Reliability
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but the equipment has high costs
Solution Approach 1:
The modular segmented design with separate mandrel tool and tooling assembly reduces equipment costs by eliminating the need for massive autoclave structures. The compact configuration requires less material and has lower manufacturing and operational costs.
Solution Approach 2:
The tooling assembly creates a simplified copy of the pressure vessel function without requiring the full-scale autoclave structure. This alternative approach achieves the same processing capability at reduced cost.
4Reliability
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but the equipment has long heat up and cool down times
Solution Approach 1:
The segmented design with a compact tooling assembly allows for faster heating and cooling cycles compared to massive autoclaves. The reduced thermal mass of the equipment enables quicker temperature changes, reducing cycle time.
Solution Approach 2:
The system is designed to enable rapid periodic heating and cooling cycles. The compact tooling assembly can be quickly heated to processing temperature and just as quickly cooled down between cycles, increasing productivity.
5Reliability
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but manual installation and removal of vacuum hoses and temperature sensors is required
Solution Approach 1:
The tooling assembly is designed as a universal multi-functional unit that integrates vacuum sealing, heating, and pressurization capabilities. This eliminates the need for separate manual operations with vacuum hoses and temperature sensors, as all functions are incorporated into the sealed vessel system.
Solution Approach 2:
The patent merges multiple functions (vacuum sealing, heating, pressurization) into a single integrated tooling assembly that seals around the mandrel tool. This combination eliminates the need for manual installation and removal of separate components between cycles.
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 apparatus reduces processing costs and cycle times, increases throughput, and allows for flexible facility layouts by minimizing the size of the processing equipment and gas volume required, while maintaining efficient application of heat and pressure.
Implementation Method 1
the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel, configured to apply at least one of pressure and heat to the composite structure
Implementation Method 2
the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel, configured to apply at least one of pressure and heat to the composite structure
Data Source
AI summary
A method of processing a composite structure includes a step of positioning a first processing tool of a tooling assembly and a second processing-tool of the tooling assembly from an open position, in which the first processing-tool and the second processing-tool are spaced apart, to a closed position, in which the first processing-tool and the second processing-tool are sealed to each other and are sealed to a mandrel-tool, supporting the composite structure, to form a vessel that surrounds the composite structure. The method also includes a step of processing the composite structure.