Composite Core Manufacturing via Thermal Expansion Mandrels

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Solution Overview

Problem

Conventional methods for manufacturing composite honeycomb cores are labor-intensive and result in suboptimal products, making them expensive and unsuitable for various structural applications.

Innovation Solution

A system and method involving the use of mandrels configured with a low coefficient of thermal expansion, automated wrapping of composite material, and a curing process that utilizes thermal expansion to apply consistent pressure, allowing for the production of composite cores with tailored geometry and properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual pressing of mandrels against composite layers is used, then honeycomb core can be manufactured, but the process is labor intensive and expensive

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical pressing process with an automated system where mandrels are inserted into a mold cavity, composite material is deposited around them, and thermal expansion provides the forming pressure. This eliminates labor-intensive manual operations while maintaining manufacturing capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes thermal expansion parameters by heating the mandrels to cause them to expand, which automatically applies pressure to form the composite material into the desired honeycomb geometry. This temperature-driven parameter change replaces manual mechanical pressing.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If manual pressing process is used, then honeycomb core can be produced, but the product is not optimal for structural implementations

Engineering Contradiction:

Improvemanufacturing feasibilityVSAvoidgeometric precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent incorporates preliminary action by designing mandrels with specific geometries that pre-define the desired honeycomb cell structure. The mandrels are prepared in advance with precise dimensions and configurations, ensuring that when composite material is deposited around them, the resulting structure achieves the required geometric precision for structural applications.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The replacement of manual pressing with a mold-based system where composite material is deposited around pre-configured mandrels allows for more consistent and precise geometric control. The mold cavity and mandrel geometry work together to ensure repeatable, high-precision honeycomb structures suitable for structural implementations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If automated mandrel wrapping and curing process is used, then productivity and quality improve, but device complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmanufacturing system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent employs thermal expansion of mandrels as the core mechanism to simplify the system. By heating the mandrels, they automatically expand to apply forming pressure on the composite material, eliminating the need for complex external pressing mechanisms. This natural physical phenomenon reduces device complexity while maintaining high productivity and quality.

Inventive Principle:

Principle #37Thermal expansion

Solution Approach 2:

The mandrels serve multiple functions automatically: they define the geometry, provide the forming pressure through thermal expansion, and support the composite material during curing. This self-service capability of the mandrels reduces the need for additional complex equipment, thereby improving productivity without proportionally increasing device complexity.

Inventive Principle:

Principle #25Self-service

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 enables efficient, cost-effective, and high-quality production of composite cores with tailored mechanical properties, reducing labor costs and improving structural suitability.

Implementation Method 1

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10131108B2System and method of manufacturing composite core

Publication Date: 2018.11.20 BELL HELICOPTER TEXTRON INC

AI summary

A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.