Composite Structure Construction via Sequential Layer Deposition

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Solution Overview

Problem

Existing technologies are inadequate for efficiently constructing larger, complex composite structures due to limitations in lamination equipment that struggle with laying up multiple geometries, angles, and sizes of layers in three-dimensional contours.

Innovation Solution

A system comprising a conveyor and multiple stations that sequentially deposit layers of composite material, allowing for the creation of complex composite structures 'off tool' without relying on a cure tool, enabling efficient curing and assembly with other components, thus reducing assembly times and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a lamination head moves in three dimensions relative to a cure tool to deposit composite material, then complex three-dimensional composite structures can be constructed, but the assembly time and cost increase significantly

Engineering Contradiction:

Improveability to construct complex three-dimensional composite structuresVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The construction process is divided into two separate stages: (1) laying up composite material layers on a flat conveyor belt to create a flat composite structure, and (2) subsequently forming and curing the structure on a cure tool. This segmentation allows the complex three-dimensional structure to be built from simpler flat layers, reducing assembly time while maintaining the ability to construct complex geometries.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The composite material layers are laid up in advance on a flat conveyor belt before being transferred to the cure tool. This preliminary action allows the layers to be prepared and positioned beforehand, enabling faster subsequent forming and curing operations, thereby reducing overall assembly time.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If a lamination head sequentially lays up multiple geometries, angles, and sizes of layers, then complex composite structures can be created, but the device complexity and cost increase

Engineering Contradiction:

Improveability to lay up multiple geometries, angles, and sizes of layersVSAvoidcomplexity of lamination equipment

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system separates the laying up function from the forming function. A simple flat conveyor belt handles the laying up of composite material layers, while a separate cure tool handles the three-dimensional forming. This segmentation simplifies the lamination equipment while maintaining the ability to create complex structures through the subsequent forming process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of moving the lamination head in three dimensions to create complex shapes directly, the invention inverts the approach by first creating flat layers on a simple conveyor and then using the cure tool to form the three-dimensional geometry. This inversion simplifies the lamination equipment while achieving the same complex structural outcomes.

Inventive Principle:

Principle #13The other way round (Inversion)

3Adaptability or versatility

If the same lamination head is used to deposit layers with different geometries and angles, then various composite structures can be constructed, but the manufacturing precision decreases

Engineering Contradiction:

Improveability to construct various composite structuresVSAvoidprecision of layer placement

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system uses a simple flat conveyor belt for laying up layers, ensuring precise and consistent layer placement on a flat surface. The subsequent forming process on the cure tool then applies localized transformations to achieve the desired three-dimensional geometry, maintaining precision in both the laying up and forming stages without requiring the lamination head to perform multiple complex functions.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10850489B2Systems and methods for constructing complex composite structures

Publication Date: 2020.12.01 THE BOEING CO

AI summary

Systems for constructing complex composite structures include a conveyor and two or more stations operatively and sequentially positioned relative to the conveyor. Each station is configured to operatively deposit a layer of composite material on the conveyor. Methods of constructing a complex composite structure include laying up a first layer of composite material having a first configuration and laying up a second layer of composite material having a second configuration at least partially over the first layer.