Composite Assembly Fixture With Anisotropic Thermal Expansion

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Solution Overview

Problem

Manufacturing composite structures, such as those used in aircraft, requires specialized and time-consuming tooling with isotropic thermal expansion properties to prevent deformation during high-temperature curing, which is costly and inefficient.

Innovation Solution

The use of additive manufacturing to create tooling with anisotropic thermal expansion properties by aligning reinforcement fibers within a fiber-reinforced thermoplastic matrix, allowing for optimized thermal expansion in specific dimensions to minimize deformation and facilitate bonding and extraction of composite components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional isotropic tooling is used for manufacturing composite structures, then thermal deformation during high-temperature curing is minimized, but manufacturing time and cost increase significantly

Engineering Contradiction:

Improvethermal deformation controlVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the thermal expansion parameters of the tooling from isotropic to anisotropic by orienting reinforcement fibers in specific directions. This allows the tooling to have different thermal expansion coefficients in different directions, matching the anisotropic thermal properties of composite materials and reducing deformation during curing while enabling faster manufacturing cycles.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite materials with oriented reinforcement fibers to create tooling that exhibits anisotropic thermal expansion properties. This composite structure allows the tooling to be tailored with specific thermal characteristics that match the workpiece, achieving both precision and productivity improvements.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If specialized tooling is designed and built for each composite structure, then manufacturing precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improvecomposite structure qualityVSAvoidtooling design complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent creates tooling with anisotropic thermal properties that can be adapted to work with various composite structures. By using composite materials with oriented fibers, the same tooling design approach can be applied across different applications, reducing the need for completely specialized tooling for each project while maintaining manufacturing precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If traditional tooling materials are used, then ease of manufacture is maintained, but thermal expansion control during high-temperature curing deteriorates

Engineering Contradiction:

Improvetooling fabricationVSAvoidthermal expansion control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent uses composite materials consisting of a matrix with oriented reinforcement fibers to create tooling with controlled anisotropic thermal expansion. This approach maintains relative ease of manufacture through established composite fabrication techniques while achieving superior thermal expansion control that matches composite workpieces during high-temperature curing.

Inventive Principle:

Principle #40Composite materials

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 significantly reduces the time and expense of building tooling, enabling faster and more efficient high-temperature curing of composite components, thereby reducing manufacturing cycle times for aircraft and other composite applications.

Implementation Method 1

the assembly fixture further comprises an anisotropic thermal expansion property based on an orientation of the plurality of reinforcement fibers within the assembly fixture

Methodology Applied

Scientific EffectAnisotropic thermal expansion: Thermal Expansion

Implementation Method 2

heating the assembly fixture in an autoclave to bond the plurality of components of the composite structure

Methodology Applied

Scientific EffectThermal curing: Heating

Data Source

PatentUS11738493B2Method of manufacturing an assembly fixture and a composite product

Publication Date: 2023.08.29 TEXTRON INNOVATIONS INC

AI summary

In one embodiment, a method includes fastening a plurality of components of a composite structure in an assembly fixture, wherein the assembly fixture comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands, and wherein the assembly fixture further comprises an anisotropic thermal expansion property based on an orientation of the plurality of reinforcement fibers within the assembly fixture; and heating the assembly fixture in an autoclave to bond the plurality of components of the composite structure.