Composite J-Beam Forming via Segmented C-Z Channel Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The labor-intensive fabrication process of composite J-beams, particularly the forming of 'Z' channels, limits production speed and increases costs, necessitating a more efficient and automated method for forming support beams.
Innovation Solution
The method involves using forming tools to bend C-shaped composite charges into J-beam configurations, with optional heating and bladder inflation to facilitate bending, and curing to form efficient support beams, allowing for increased automation and reduced labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hand lay up fabrication method is used for Z channels, then manufacturing flexibility is maintained, but productivity is low and labor costs increase
Solution Approach 1:
The patent divides the J-beam fabrication into separate C-channel and Z-channel components that are formed independently and then joined. This segmentation allows each component to be manufactured using optimized processes (C-channels via elastomeric membrane hot forming, Z-channels via hand lay-up), resolving the contradiction by enabling automated production of critical components while maintaining manual fabrication where flexibility is needed.
Solution Approach 2:
The patent combines multiple Z-channels and C-channels into a composite assembly that forms the complete J-beam structure. This merging allows the structure to achieve the strength and stiffness of a monolithic beam while utilizing efficient automated forming processes for the C-channel components, thereby improving productivity without sacrificing structural integrity.
2Ease of manufacture
If hand lay up method is used for Z channel fabrication, then process simplicity is maintained, but production costs increase
Solution Approach 1:
By segmenting the J-beam into C-channel and Z-channel components, the patent allows Z-channels to be fabricated using simple hand lay-up methods while C-channels are produced through efficient elastomeric membrane hot forming. This segmentation resolves the contradiction by applying manual fabrication only where necessary while automating high-volume production steps.
Solution Approach 2:
The patent performs preliminary forming of C-channels using elastomeric membrane hot forming to create pre-shaped components that can be quickly assembled with hand-laid Z-channels. This preliminary action reduces the overall fabrication time and complexity, improving production efficiency without requiring complex automated systems for the entire structure.
3Weight of moving object
If composite materials are used for J-beam fabrication, then weight reduction is achieved, but forming complexity increases
Solution Approach 1:
The patent segments the composite J-beam into C-channel and Z-channel components that can be formed using different specialized processes. C-channels are formed via elastomeric membrane hot forming while Z-channels use hand lay-up, allowing each component to be optimized for its specific geometry and reducing the overall forming complexity compared to creating a monolithic composite structure.
Solution Approach 2:
The patent utilizes composite materials for both C-channel and Z-channel components, maintaining the weight advantage of composites while managing forming complexity through component segmentation. The composite structure is achieved through assembling pre-formed composite components rather than forming a single complex composite piece, thereby reducing 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
This approach enhances production efficiency and reduces costs by automating the fabrication of composite J-beams, enabling faster and more cost-effective production of support beams.
Implementation Method 1
Composite C channels are formed, among other ways, with an elastomeric membrane hot forming machine
Implementation Method 2
The bending of a second portion of the additional charge may include inflating at least one bladder proximate the first forming tool
Implementation Method 3
The method may include heating the first forming tool, the fixed forming tool, or both prior to formation of the support beam
Implementation Method 4
The method may include curing the support beam once the second portion of the additional charge is bent
Data Source
AI summary
A method of forming a support beam is provided. One exemplary method of forming a support beam includes supporting a C-shaped charge upon a first forming tool and placing an additional composite charge upon at least a portion of the C-shaped charge and a second forming tool proximate the first forming tool. The method of forming a support beam further includes positioning a fixed forming tool proximate a first portion of the additional charge and bending the additional charge about the forming tool.