Composite Laminate Forming Sequence for Wrinkle Suppression
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Solution Overview
Problem
Existing methods for manufacturing composite structures face challenges in suppressing the generation of wrinkles during deformation processing, which reduces the strength of the final product, and are often complicated due to the need for laminating fiber sheets on non-planar molds.
Innovation Solution
A method involving a lamination step followed by forming recessed and projecting portions with curved surfaces, then deforming the laminate in lateral and longitudinal directions to create a composite structure with predetermined shapes, using fiber sheets laminated in a thickness direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-planar portion is formed in the laminate before deformation processing, then wrinkle generation is suppressed, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by forming a non-planar portion (recessed or projecting portion) in the laminate before performing deformation processing. This pre-formed non-planar portion serves as a guide structure that prevents wrinkle generation during subsequent deformation operations, thereby improving reliability while maintaining processability through a systematic sequence of operations.
Solution Approach 2:
The patent segments the manufacturing process into distinct stages: first forming the non-planar portion through localized deformation, then performing the main deformation processing. This segmentation allows the complex wrinkle-suppression function to be achieved through a separate, controlled operation rather than attempting to accomplish everything in a single complex process.
2Shape
If fiber sheets are laminated on a non-planar mold, then the laminate achieves the desired shape, but the molding work becomes complicated
Solution Approach 1:
The patent inverts the conventional approach by first laminating fiber sheets on a planar mold to create a flat laminate, then forming the non-planar portion through controlled deformation operations. This reversal of the traditional sequence (planar molding → non-planar shaping) simplifies the molding work while achieving the desired final shape through subsequent deformation processing.
Solution Approach 2:
The patent performs preliminary lamination on a planar mold before forming the non-planar portion. This preliminary action establishes a simple, easy-to-manufacture base laminate that can then be deformed into the final desired shape, avoiding the complexity of laminating directly on a non-planar mold.
3Ease of manufacture
If the laminate is deformed without pre-formed non-planar portions, then the manufacturing process is simpler, but wrinkles are generated reducing strength
Solution Approach 1:
The patent applies preliminary action by forming non-planar portions before deformation processing. This pre-formed structure guides the deformation process and prevents wrinkle generation, thereby maintaining strength while the overall process remains systematically simple through clear operational sequencing.
Solution Approach 2:
The patent applies preliminary anti-action by creating non-planar portions that counteract the tendency of the laminate to develop wrinkles during deformation. These pre-formed portions act as protective structures that prevent the harmful wrinkle formation, thereby preserving the strength of the final composite structure.
Data Source
AI summary
The purpose of the present invention is to further enhance the strength of a manufactured composite structure by further suppressing the occurrence of wrinkling. A method for manufacturing a composite structure, the method comprising: a lamination step for layering a plurality of fiber sheets and molding a plate-form laminate; a forming step for forming a recess formed by a curved surface in a prescribed portion of the laminate; a short-direction deformation step for deforming the laminate in the short direction thereof after the forming step to configure a long-direction cross-section of the laminate in a prescribed shape; and a long-direction deformation step for deforming the laminate in the long direction after the forming step, so that the recess formed in the forming step deforms, to configure a short-direction cross section in a prescribed shape.