Compaction Roller Cleaning via Scrubbing and Drying Rollers

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Solution Overview

Problem

The manual compaction of ceramic matrix composite plies results in variable quality and inconsistencies, with remnants and debris often remaining on the surface of compaction rollers, requiring inefficient manual removal and increasing the life cycle time for compaction.

Innovation Solution

A method and system utilizing a scrubbing roller and a drying roller to efficiently clean ceramic matrix from compaction rollers, involving the application of a cleaning fluid, scrubbing to remove debris, and drying to remove the fluid and debris.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual compaction operations are used with hand pressure and sweeping, then the process requires skilled technicians and allows flexibility, but the quality is variable and inconsistencies occur

Engineering Contradiction:

Improvecompaction quality consistencyVSAvoidmanual operation complexity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent replaces manual mechanical compaction operations with an automated mechanical system consisting of a compaction roller mounted on a robotic end effector. The robotic system provides consistent, repeatable compaction forces while the integrated cleaning system automatically removes debris, eliminating quality variations associated with manual operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The compaction roller is equipped with an integrated cleaning system that automatically removes ceramic matrix debris from its surface during or after the compaction process. This self-cleaning capability ensures consistent compaction quality across multiple plies without requiring manual intervention to clean the roller between operations.

Inventive Principle:

Principle #25Self-service

2Productivity

If manual sweeping and vacuum bagging techniques are used to remove debris, then the process uses simple equipment, but the time required increases and productivity decreases

Engineering Contradiction:

Improvecompaction cycle timeVSAvoiddebris removal time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The cleaning system operates continuously during or immediately after the compaction process, rather than requiring separate manual sweeping and vacuuming steps. The scrubbing roller and suction mechanism work in tandem to continuously remove debris from the compaction roller surface, eliminating idle time between compaction operations.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent combines the compaction function and cleaning function into a single integrated system. The compaction roller, scrubbing roller, and suction mechanism work together as one unit, merging what were previously separate operations (compaction, sweeping, and vacuuming) into a single automated process that reduces total cycle time.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If a compaction roller is used to compact ceramic matrix composite plies, then the compaction quality improves, but debris remains on the roller surface requiring removal

Engineering Contradiction:

Improvecompaction uniformityVSAvoidroller surface debris

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a scrubbing roller as an intermediary element between the compaction roller and the debris removal system. The scrubbing roller, equipped with cleaning fluid delivery and suction, acts as a mediator that transfers debris from the compaction roller surface without requiring direct contact or manual intervention, thereby maintaining compaction quality while effectively removing harmful debris.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Productivity

If automated compaction rollers are used, then productivity increases, but the complexity of the system increases

Engineering Contradiction:

Improvecompaction throughputVSAvoidcleaning system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The compaction roller assembly is designed as a multi-functional unit that performs both compaction and self-cleaning operations. The robotic end effector can accommodate different roller configurations for various compaction needs, while the integrated cleaning system handles multiple functions (fluid delivery, scrubbing, and suction) through a single standardized interface, reducing overall system complexity despite increased capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively cleans the compaction rollers, ensuring consistent quality in ceramic matrix composite compaction, reducing manual labor, and decreasing the overall life cycle time for compaction operations.

Implementation Method 1

scrubbing the compaction roller to remove ceramic particles of the ceramic matrix from a compaction-roller surface of the compaction roller

Methodology Applied

Scientific EffectMechanical scrubbing: Abrasion

Implementation Method 2

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

Methodology Applied

Scientific EffectMechanical drying: Absorption (physical)

Data Source

PatentUS20250170616A1Systems and methods for cleaning ceramic matrix from a compaction roller

Publication Date: 2025.05.29 THE BOEING CO

AI summary

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