Composite Material Jig With Segmented Rigidity for Wrinkle Control
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Solution Overview
Problem
Composite materials with curved portions in aircraft components face issues with pressure application during processing, leading to wrinkles and shape defects due to mismatched rigidity between pressurizing blocks and the material, resulting in incomplete pressure distribution and reduced structural strength.
Innovation Solution
A jig with a first contact part of lower rigidity and a second contact part of higher rigidity, designed to deform and match the curved shape of the composite material, ensuring uniform pressure application and minimizing wrinkles by contacting the material at specific regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a pressurizing block with high rigidity is used to apply pressure to the curved portion of the composite material, then the pressure can be applied to the curved portion, but gaps are formed between the pressurizing block and the curved portion, resulting in incomplete pressure application
Solution Approach 1:
The pressurizing block is divided into multiple pressing portions with different rigidity characteristics. The first pressing portion has high rigidity to apply sufficient pressure to the curved portion, while the second pressing portion has lower rigidity to conform to the curved shape and eliminate gaps, ensuring uniform pressure distribution across the composite material surface.
Solution Approach 2:
Different portions of the pressurizing block are assigned different rigidity properties based on their functional requirements. The first pressing portion (high rigidity) targets areas requiring strong pressure application, while the second pressing portion (low rigidity) targets areas requiring conformal contact and pressure distribution uniformity, creating a non-uniform rigidity distribution optimized for the specific geometry of the composite material.
2Manufacturing precision
If a pressurizing block with low rigidity is used to conform to the curved shape of the composite material, then the block can eliminate wrinkles, but the block itself deforms under pressure, reducing its ability to eliminate wrinkles
Solution Approach 1:
The pressurizing block is segmented into multiple pressing portions with differentiated rigidity. The first pressing portion maintains high rigidity to provide structural support and prevent excessive deformation, while the second pressing portion uses lower rigidity to conform to the curved composite material surface and eliminate wrinkles through controlled deformation and pressure distribution.
Solution Approach 2:
The pressurizing block exhibits spatially varying rigidity properties where the first pressing portion (high rigidity) provides structural stability, and the second pressing portion (low rigidity) provides wrinkle elimination capability through local conformity to the composite material surface, achieving both structural integrity and surface quality.
3Force
If a rigid pressurizing block is used to apply pressure to the composite material, then pressure can be applied to the curved portion, but the shape of the composite material cannot be accurately formed due to gaps
Solution Approach 1:
The pressurizing block is divided into multiple pressing portions with different rigidity characteristics. The first pressing portion applies pressure to the curved portion while the second pressing portion conforms to the composite material shape, working together to eliminate gaps and achieve accurate shape formation through distributed pressure application.
Solution Approach 2:
Different regions of the pressurizing block have different rigidity properties optimized for their specific functions: the first pressing portion (high rigidity) ensures pressure application to curved areas, while the second pressing portion (low rigidity) ensures conformal contact for shape accuracy, resulting in precise composite material forming.
Data Source
AI summary
A block is configured such that, when a composite material having a curved part in a cross-sectional shape cut by a plane orthogonal to an X-axis is deformed into a shape corresponding to a mold through pressure application while being kept in the mold, the block is brought into contact with the curved part of the composite material. The block includes: a first contact part which extends along the X-axis direction so as to be in contact with the curved part of the composite material; and a second contact part which is partially disposed along the X-axis direction, is in contact with the curved part of the composite material, and is of higher rigidity than the first contact part.