Composite Laminate Panel Sub-Elements Standardized Coupling Profiles
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Solution Overview
Problem
The conventional method of manufacturing large composite laminate modular structures is complex, time-consuming, and costly, requiring numerous customized molds and unique coupling profiles, which limits scalability and efficiency in production and assembly.
Innovation Solution
A method for manufacturing composite laminate panel sub-elements using elongate composite laminate sheet panels, where sections are cut and machined to create standard panel sub-elements with pre-defined coupling profiles, allowing for assembly without a supporting framework, and utilizing a minimal number of molds and standard sizes, enabling faster and more efficient production and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to manufacture large composite laminate modular structures, then the structures can be assembled, but the manufacturing process is complex, time-consuming, and costly requiring numerous customized molds and unique coupling profiles
Solution Approach 1:
The patent applies universality by introducing standard panel sub-elements with standardized coupling profiles that can be used across multiple different structures and configurations. Instead of creating unique customized molds and coupling profiles for each structure, the same standard panels can be reused universally, thereby reducing manufacturing complexity and the number of specialized tools required
Solution Approach 2:
The patent segments large composite laminate structures into smaller standard panel sub-elements that can be manufactured independently using a limited number of standard molds. These segmented panels are then assembled into larger structures through standardized coupling profiles, simplifying the overall manufacturing process and reducing the need for numerous customized molds
2Adaptability or versatility
If conventional methods are used with numerous customized molds, then unique structures can be created, but production time and costs increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-manufacturing standard panel sub-elements with standardized coupling profiles that can be stored and quickly assembled into different structures. This preliminary preparation of standardized components eliminates the need for time-consuming customization during final assembly, thereby reducing production time and costs while maintaining design flexibility
Solution Approach 2:
The patent changes the parameter of coupling profiles from unique customized designs to standardized configurations. This parameter change allows for faster manufacturing using standard molds and enables quicker assembly processes, thereby improving productivity while still allowing for structural adaptability through different panel arrangements
3Manufacturing precision
If unique coupling profiles are used for each panel, then precise fitting is achieved, but assembly complexity and time increase
Solution Approach 1:
The patent applies copying by using standardized coupling profiles that are replicated across multiple panel sub-elements. Instead of creating unique coupling profiles for each panel, the same standardized coupling design is copied and applied to all panels, ensuring consistent fitting accuracy while dramatically reducing assembly complexity and time
4Productivity
If standard panel sub-elements are used instead of customized molds, then production efficiency improves, but the number of standard sizes must be limited
Solution Approach 1:
The patent applies dimensionality change by standardizing the panel thickness dimension while allowing variability in length and width dimensions. This approach maintains production efficiency through standardized manufacturing processes for the critical thickness dimension, while still providing adaptability through customizable length and width variations of the standard panels
Data Source
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AI summary
A method of manufacturing composite laminate panel sub- elements (34) for subsequent assembling into a modular assembly structure (37), comprises the preprocessing steps of casting an elongate composite laminate sheet panel (18) having opposite first and second fiber-reinforced plastic face skins (19,21) sandwiching a core (35), a free first elongate edge (22) and an opposite second elongate free edge (24), demolding the elongate composite laminate sheet panel (18), cutting the demolded elongate composite laminate sheet panel (18) into (n) shorter sections (Sn), thereby providing sections (Sn) with at least one free cut edge (26; 32), a free first edge (22) having the same profile as the free first elongate edge, and a free second edge (22) parallel to the free first edge and having the same profile as the free second elongate edge, and machining at least a first coupling profile (27) along the at least one free cut edge (26; 32).