Composite Core Post-Cure Cutting via Mandrel Thermal Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional cutting of bulk composite core is labor-intensive and results in significant waste, with shapes often distorting during the process, necessitating an improved system and method for post-cure processing.
Innovation Solution
A method and system for manufacturing composite cores using mandrels with controlled thermal expansion, automated wrapping, and curing processes, followed by efficient cutting techniques to minimize distortion and waste, including the use of fixtures and adhesives for supporting the core during cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cutting methods are used on bulk composite core, then the core can be divided into slices, but the process becomes labor-intensive and results in significant material waste
Solution Approach 1:
The patent applies preliminary action by pre-forming the composite core into a net-shape configuration during the curing process using a mold that matches the final desired geometry. This eliminates the need for subsequent cutting operations, thereby improving productivity while eliminating material waste that would otherwise be generated during cutting.
2Manufacturing precision
If conventional cutting methods are used on bulk composite core, then slices can be obtained, but the shapes tend to distort during the cutting process
Solution Approach 1:
The patent pre-forms the composite core into its final net-shape configuration during curing, eliminating subsequent cutting operations that would cause shape distortion. This ensures manufacturing precision is achieved during the forming stage rather than requiring post-cure cutting that compromises shape stability.
3Ease of manufacture
If bulk composite core is cut into usable slices, then the material can be utilized, but the process requires significant labor input
Solution Approach 1:
The patent performs the shaping operation preliminarily during the curing process itself, forming the final net-shape configuration before the composite fully cures. This eliminates the need for separate cutting operations, thereby simplifying the manufacturing process and reducing total processing time while maintaining ease of manufacture.
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 reduces labor and waste, enhances the precision and quality of cut composite wafers, and allows for the efficient processing of composite cores into usable shapes with minimized distortion and increased yield.
Implementation Method 1
mandrels with controlled thermal expansion
Data Source
AI summary
A method of cutting a wafer of composite core from a bulk composite core including the steps of placing the bulk composite core in a container, the bulk composite core having a plurality of tube members; depositing a potting compound in contact with an outer surface of the bulk composite core; curing the potting compound; and after curing of the potting compound, cutting through each of the tube members. A method of cutting a wafer of composite core from a bulk composite core, the method comprising the steps of stabilizing the bulk composite core by wrapping an exterior of the bulk composite core with a composite wrap, the bulk composite core having a plurality of tube members; curing the composite wrap; and cutting through each of the tube members.