Compacted Stringer Package Construction via Vacuum Compression
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Solution Overview
Problem
Conventional composite stringer manufacturing processes are time and labor intensive, requiring separate processing and installation of components, which limits the production quantity of aircraft.
Innovation Solution
A system and method for constructing a compacted stringer package using a compression housing with a tray and lid that forms a sealed chamber, allowing for the arrangement and vacuum compaction of composite charge, bladder, and radius fillers to form a compacted stringer package, enabling single installation onto a cure tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional separate processing and installation of composite stringer components is used, then manufacturing precision and quality control are maintained, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent combines multiple separate components (composite stringer, bladder, radius fillers) into a single integrated package that is processed and installed as one unit. This merging eliminates the need for separate processing and installation steps, directly reducing manufacturing time while maintaining quality through controlled packaging conditions.
Solution Approach 2:
The composite stringer, bladder, and radius fillers are pre-assembled into a complete package before installation on the cure tool. This preliminary assembly allows all components to be prepared and positioned simultaneously, eliminating sequential processing time and accelerating manufacturing without compromising precision.
2Manufacturing precision
If multiple separate processing steps are used for composite stringer components, then manufacturing precision is maintained, but device complexity and process difficulty increase
Solution Approach 1:
By integrating the composite stringer, bladder, and radius fillers into a single packaged unit, the patent reduces process complexity from multiple separate operations to a single installation step. The packaging structure itself provides the precision alignment features, eliminating the need for complex alignment procedures.
Solution Approach 2:
The packaging structure serves as an intermediary that pre-positions and aligns all components with precision before installation. This intermediary package handles the complexity of component arrangement externally, allowing the main installation process to be simple while maintaining manufacturing precision.
3Productivity
If conventional multi-step compaction process is used, then manufacturing precision is maintained, but productivity is reduced
Solution Approach 1:
The patent merges multiple compaction operations into a single compaction step by providing all components (composite stringer, bladder, radius fillers) in a pre-assembled package. This eliminates the need for sequential compaction of individual components, reducing total compaction time and increasing production quantity.
Solution Approach 2:
The components are pre-assembled and pre-positioned in the package before the compaction process. This preliminary arrangement ensures that all components are ready for simultaneous compaction, eliminating the time required for sequential compaction operations and boosting productivity.
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 method significantly reduces manufacturing time by compacting all necessary components in a single step, enhancing efficiency and enabling faster production of aircraft stringers.
Implementation Method 1
applying vacuum to a sealed chamber formed by a compression layer and a lid of the compression housing
Implementation Method 2
the breather layer distributes vacuum within the sealed chamber
Implementation Method 3
the lid and the compression layer form a sealed chamber
Implementation Method 4
compacting, by applying vacuum, the composite stringer package between the compression layer and the lid
Implementation Method 5
compact the composite stringer package within the compression housing to form a compacted stringer package
Data Source
AI summary
A system for constructing a compacted stringer package includes a compression housing that includes a tray and a lid that is movable relative to the tray such that the compression housing is in an open state or in a closed state. The system includes a compression layer that is positioned over the tray. The system includes a breather layer that is positioned over the compression layer. With the compression housing in the closed state, the lid and the compression layer form a sealed chamber. With the compression housing in the closed state, the breather layer is positioned between the lid and the compression layer and within the sealed chamber. With the compression housing in the closed state, the breather layer distributes vacuum within the sealed chamber.