Composite Component Joining With In-Situ Thermoforming Fit
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Solution Overview
Problem
Existing methods for joining composite components in aircraft construction, such as ramped aircraft skins with joggled stringers, are complex and require additional preforming steps, leading to increased costs and manufacturing time.
Innovation Solution
A method involving a dimensionally stable component with a first joining surface and a second component with a reactable binder system, which is deformed to match the first surface under pressure and heat, allowing in-situ thermoforming and consolidation without preforming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If preforming is used to create the correct geometry for the stiffener, then the positioning accuracy is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The stiffener is preformed in advance as a separate component with standardized geometry, allowing for precise manufacturing and quality control before the final assembly stage
Solution Approach 2:
The deformation and joining operations are merged into a single integrated process step, where the stiffener is deformed and attached to the skin in one operation, eliminating separate preforming and assembly steps
2Manufacturing precision
If preforming is performed as a separate step, then the geometry accuracy is improved, but the manufacturing time increases
Solution Approach 1:
Multiple manufacturing operations (deformation, positioning, and joining) are merged into a single integrated process step, reducing the total number of process steps and manufacturing time
Solution Approach 2:
The stiffener is preformed in advance with standardized geometry, allowing for efficient batch production and reducing the time required during final assembly
3Ease of manufacture
If standardized components are used, then the manufacturing cost is reduced, but the fit accuracy to the specific geometry decreases
Solution Approach 1:
The physical state of the binder system is changed through temperature and pressure application, transforming it from a rigid standardized component to a deformable state that can adapt to the specific geometry of the skin
Solution Approach 2:
The binder system transitions from a static standardized component to a dynamic state during processing, where it can be deformed and molded to fit the specific geometry while maintaining standardized manufacturing benefits
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 method simplifies the manufacturing process by eliminating the need for preforming, reducing time and costs, and ensures precise fit without positioning issues, applicable in aircraft, boat building, and automotive engineering.
Implementation Method 1
at least a binder system, which is in particular reactable under temperature, which is dimensionally stable before processing... deforming the second component so that the second joining surface follows the shape of the first joining surface of the first component by applying pressure and heat
Implementation Method 2
joining the second and the first components by applying pressure and heat
Implementation Method 3
by applying pressure and heat
Data Source
Figure 1~3
AI summary
The invention relates to an in-situ thermoforming and (co-)consolidation, wherein a pre-deformation of a plastic-based component (2) in order to correspondent to a contour of a component (1) to be joint with can be omitted, as the adaption of the component (2) to the contour of the component (1) to be joint with is done directly before the joining step with the other component in the same tooling (12, 13) by adapting process parameters such as heat and pressure.