Composite J-Beam Fabrication Using Segmented Tooling
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Solution Overview
Problem
The existing methods for fabricating composite J-beams require complex and costly tooling with tight tolerances, making them inefficient and costly for producing beams with nonsymmetrical cross sections like the J-beam, which demands a simpler and cost-effective approach to maintain dimensional stability and performance.
Innovation Solution
A method using a set of matched tools to preform and mold composite charges into C-channels and Z-channels, with the layup cured between these tools, allowing for the fabrication of J-beams with a minimum number of tools, ensuring good dimensional stability and performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex tooling with tight tolerances is used to fabricate composite J-beams, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The tooling system is segmented into a minimum set of simple components that can be reused for multiple operations. Instead of using complex dedicated tooling for each beam feature, the patent divides the tooling into basic elements (support tools, forming tools, curing tools) that can be combined in different configurations to produce C-channels, Z-channels, and assembled J-beams, thereby reducing overall device complexity while maintaining manufacturing precision
Solution Approach 2:
The simple tooling components are designed to perform multiple functions. The same support tools and forming tools used to create C-channels and Z-channels are also used to assemble and cure the final J-beam structure. This multi-functionality reduces the total number of tools required and eliminates the need for complex specialized tooling for each manufacturing stage
2Manufacturing precision
If multiple steps and complex tooling are used to form C-channel and Z-channel features, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
C-channels and Z-channels are preformed as separate components using simple tooling before final assembly. This preliminary action allows each component to be formed independently with basic tools, avoiding the need for complex multi-step forming operations on the final assembly, thereby improving productivity while maintaining feature accuracy through controlled preforming processes
Solution Approach 2:
The patent combines multiple manufacturing operations into a streamlined sequence where preformed C-channels and Z-channels are assembled and cured together in the same tooling setup. This merging of assembly and curing steps eliminates the need for separate complex tooling for each operation, improving productivity without sacrificing feature formation accuracy
3Manufacturing precision
If additional tools are used to assemble, mold and cure the layup, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The same simple support tools and forming tools used during the preforming of C-channels and Z-channels are reused for assembling, molding, and curing the final J-beam layup. This universal application of basic tooling components eliminates the need for additional specialized tools, reducing device complexity while maintaining assembly and curing accuracy through consistent tooling applications
Data Source
AI summary
Three simple tools are used to both preform and mold a composite layup into a J-beam. A first composite charge is preformed into a C-channel using a first tool, and a second composite charge is formed into a Z-channel using both the first tool and a second tool. The C-channel and Z-channel are laid up between the first and second tools, following which a perform composite cap and third tool are added to complete the layup and the tool assembly. The layup may be molded using vacuum bagging techniques and subsequently cured while held in the tool assembly.