Composite Layer Forming with Compressible Supports
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Solution Overview
Problem
The repeated stretching of flexible sheets used in forming composite layers often leads to tears or openings, reducing their lifespan and necessitating frequent replacements, which disrupts the manufacturing process of composite parts, especially in aerospace applications where consistency and efficiency are critical.
Innovation Solution
The use of compressible supports positioned under the stack of composite layers to maintain a flat shape before applying a vacuum load, reducing the stress on the flexible sheet and extending its lifespan by minimizing stretching and wrinkling during the shaping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible sheet is used to form composite layers under vacuum load, then the composite layers can be consolidated into the desired shape, but the flexible sheet may tear or open after repeated use due to stress from stretching
Solution Approach 1:
The composite layers are pre-formed into a substantially flat configuration on the support structure before the forming process begins. This preliminary positioning ensures that when the flexible sheet is later stretched under vacuum load, it encounters minimal resistance and wrinkling, reducing stress on the flexible sheet and extending its usable lifespan
Solution Approach 2:
A support structure is introduced as an intermediary element between the composite layers and the forming tool. This support structure maintains the flat configuration of composite layers and distributes the stress during forming, preventing direct stress concentration on the flexible sheet that would cause tearing or opening
2Productivity
If the flexible sheet is stretched repeatedly to form shapes, then the composite parts can be manufactured, but the flexible sheet develops tears or openings requiring replacement
Solution Approach 1:
The composite layers are pre-positioned in a substantially flat configuration on the support structure before the forming operation. This preliminary arrangement allows the flexible sheet to be stretched more easily and uniformly, reducing wear and extending its service life, thereby maintaining manufacturing efficiency without frequent replacements
Solution Approach 2:
The support structure modifies the physical parameters of the forming process by maintaining a flat configuration of the composite layers. This changes the stress distribution pattern on the flexible sheet from concentrated and irregular to distributed and uniform, reducing fatigue and extending the flexible sheet's operational lifespan
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 solution allows for the consistent formation of composite parts with extended flexible sheet lifespan, reducing manufacturing downtime and costs by maintaining the integrity of the shaping process and improving the quality of composite parts.
Implementation Method 1
a vacuum load may be applied on the stack of composite layers on the tool and the number of compressible supports using the flexible sheet such that consolidation of the stack of composite layers occurs
Data Source
AI summary
A method and apparatus for forming a stack of composite layers into a desired shape is present. The stack of composite layers may be positioned on a tool and a number of compressible supports such that the stack of composite layers may be substantially flat on the tool and the stack of composite layers may be substantially flat on the number of compressible supports. A flexible sheet may be placed on top of the stack of composite layers. A vacuum load may be applied on the stack of composite layers on the tool and the number of compressible supports using the flexible sheet such that consolidation of the stack of composite layers occurs to form a desired shape on the tool and the number of compressible supports compress during forming of the desired shape.