Composite Laminate Pocket Formation With a Separating Layer

Solution Overview

Problem

Manufacturing components with locally varying thicknesses from composite materials is challenging due to high costs, tool wear, and time consumption in conventional methods, and results in problematic resin flow fronts and uneven temperature gradients.

Innovation Solution

A method involving laminate arrangements with a separating layer to prevent bonding, allowing for easy detachment of sections by guiding a cutting tool along the contour of the separating layer, reducing tool wear and time, and maintaining fiber integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If material is removed across the surface using cutting tools to create pockets, then pockets can be created in composite components, but significant stress is placed on the cutting tool leading to wear and tear and the process is time-consuming

Engineering Contradiction:

Improveease of creating pocketsVSAvoidtime consumption

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The separating layer is incorporated into the laminate arrangement before the final component is manufactured. This preliminary placement allows the pocket to be created simply by cutting along the contour of the separating layer, rather than requiring time-consuming material removal across the surface after manufacturing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The separating layer acts as an intermediary element that defines the pocket boundary. By guiding the cutting tool along the contour of this separating layer, the process transforms complex surface material removal into a simpler contour-following cutting operation, significantly reducing time consumption.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If material is removed across the surface using cutting tools to create pockets, then pockets can be created in composite components, but significant stress is placed on the cutting tool leading to wear and tear

Engineering Contradiction:

Improveease of creating pocketsVSAvoidtool wear

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The separating layer is incorporated into the laminate arrangement before the final component is manufactured. This preliminary placement allows the pocket to be created simply by cutting along the contour of the separating layer, rather than requiring time-consuming material removal across the surface after manufacturing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The separating layer acts as an intermediary element that defines the pocket boundary. By guiding the cutting tool along the contour of this separating layer, the process transforms complex surface material removal into a simpler contour-following cutting operation, significantly reducing time consumption.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Shape

If varying thicknesses are used in components manufactured using RTM or from prepregs, then locally varying thicknesses can be achieved, but problematic resin flow fronts or uneven temperature gradients result

Engineering Contradiction:

Improvelocally varying thicknessVSAvoidresin flow and temperature uniformity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The laminate arrangement is segmented into multiple layers with the separating layer positioned between specific layers. This segmentation allows the separating layer to be removed to create pockets while maintaining uniform thickness in the remaining laminate structure, thereby preventing problematic resin flow fronts and uneven temperature gradients.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separating layer is positioned only in specific locations where pockets are required, while maintaining uniform thickness in the rest of the laminate arrangement. This local application of thickness variation ensures that resin flow and temperature distribution remain uniform in the bulk material while still achieving the desired local geometry.

Inventive Principle:

Principle #3Local quality

4Loss of time

If a separating layer is introduced to prevent bonding between laminate arrangements, then tool wear and time are reduced, but the device complexity increases

Engineering Contradiction:

Improvemanufacturing timeVSAvoidlaminate arrangement complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The separating layer is implemented as a thin film or layer that can be easily integrated into the laminate arrangement. This thin-film approach adds minimal complexity while effectively preventing bonding in the required areas and enabling simple contour-based cutting operations.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The separating layer can be implemented as a disposable or single-use element that is removed after serving its purpose of preventing bonding and defining the pocket contour. This approach adds complexity only temporarily during manufacturing, after which the separating layer is removed and the final component is formed.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

The method significantly reduces tool wear, lowers costs, and minimizes time required to create recesses while preserving mechanical properties and preventing fiber damage.

Implementation Method 1

The separating layer is designed to prevent the two laminate arrangements from bonding in the relevant separation section

Methodology Applied

Scientific EffectAdhesion prevention: Adhesive

Implementation Method 2

the two laminate arrangements could either harden together or fuse at the interface between the first and second surfaces due to softening or melting of the matrix material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

applying heat and/or pressure to the two overlapping components

Methodology Applied

Scientific EffectThermal energy: Heating

Implementation Method 4

applying heat and/or pressure to the two overlapping components

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentEP4272954B1Method for producing a component from a composite material having locally different thicknesses

Publication Date: 2026.03.18 PREMIUM AEROTECH GMBH

Figure 1a~1e
Figure 2~3b

AI summary

A method for manufacturing a component from a composite material with locally varying thicknesses comprises the steps of providing a first laminate arrangement, arranging a separating layer on at least one separation section of a first surface of the first laminate arrangement, providing a second laminate arrangement having a second surface that correlates with the first surface of the first laminate arrangement, placing the second laminate arrangement with its second surface onto the first surface of the first laminate arrangement such that the at least one separation section is enclosed, joining the first laminate arrangement to the second laminate arrangement by heating and/or pressing, and guiding a cutting tool along at least one contour in the second laminate arrangement that correlates with the at least one separation section, such that at least one portion of the second laminate arrangement is completely separated.and the removal of at least one detached section, so that a depression is created in each case.