Composite Flange Forming Apparatus with Expansion Device
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Solution Overview
Problem
Current processes for forming flanges on composite components are labor-intensive and operator-dependent, and existing machines are limited in fabricating small bends or angles, making it difficult to produce high-quality flanges with small bend radii efficiently.
Innovation Solution
A method and apparatus that involve coupling composite materials to a mold with a forming element and pressure element, using expansion devices to impart force and create flanges with a bend radius less than 10 inches, allowing for the integration of flanges with precise angles and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional processes use separate metallic pieces bolted in position to form flanges, then assembly is facilitated, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent merges the flange and the composite component into a single integral structure by forming the flange directly from composite material layers during the manufacturing process, eliminating the need for separate metallic pieces and bolting operations. This combining approach reduces assembly complexity while maintaining the structural integrity and functionality of the flange.
2Ease of operation
If operators sequentially stack composite materials by hand to form flanges, then flexibility in material placement is achieved, but productivity decreases and quality becomes operator-dependent
Solution Approach 1:
The patent replaces manual mechanical stacking operations with an automated fiber placement system that uses computer-controlled mechanisms to deposit composite materials layer by layer. This substitution maintains the precision and flexibility of hand-laying while dramatically increasing productivity and eliminating operator-dependent quality variations through automated process control.
3Adaptability or versatility
If existing machines are used to fabricate flanges, then standard manufacturing capabilities are available, but the ability to create small bends or angles is limited
Solution Approach 1:
The patent employs a forming apparatus with dynamically adjustable forming elements that can be positioned and shaped to match the specific geometry required for small bend radii. The system uses controllable forming forces applied during the composite material curing process to achieve precise small bends and angles that exceed the capabilities of conventional static manufacturing equipment.
4Productivity
If automatic or semi-automatic laying up of flanges is attempted, then labor intensity is reduced, but the process becomes slow and difficult due to machine limitations
Solution Approach 1:
The patent integrates multiple functions into a single automated fiber placement system that combines material deposition, forming, and curing capabilities. This multi-functional approach eliminates the need for separate operations and complex machine changes, enabling efficient automatic laying up while maintaining the flexibility to handle various flange geometries and reducing overall process complexity.
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
Enables the efficient and precise manufacturing of flanged composite components with small bend radii, improving the quality and reducing the dependency on manual labor, thus overcoming the limitations of existing methods.
Implementation Method 1
expanding the first expansion device to impart a force to the second composite material to move the second composite material away from the composite structure and into the space
Data Source
AI summary
A method of manufacturing a flanged composite component is provided. The method includes coupling a composite structure to s first composite material. The method includes coupling a second composite material to the composite structure and placing a first expansion device within the composite structure. A forming element is coupled to at least one of the first composite material, the composite structure, and the second composite material against the mold. The method includes coupling a pressure element to the forming element to define a space among the mold, the forming element, and the pressure element. The method includes expanding the first expansion device to impart a force to the second composite material to move the second composite material away from the composite structure and into the space to facilitate forming a first flange.