Composite Noodle Ring Compaction for Precise Cavity Consolidation
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Solution Overview
Problem
Conventional methods for compacting composite components, such as those used in gas turbine engines, require complex equipment and are imprecise, leading to cumbersome and inefficient processes.
Innovation Solution
A compaction system and method involving a noodle and noodle ring, where the noodle ring is positioned complementary to the noodle and compacted using a plunger to apply precise force, allowing for controlled compaction of laminates and noodles into cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional vacuum/positive pressure debulk methods or press methods are used, then composite components can be compacted, but the equipment becomes complex and the process becomes cumbersome
Solution Approach 1:
The compaction system divides the tooling into separate, modular components: a stationary lower tool and a movable upper tool. This segmentation allows each tool to be optimized independently and simplifies the overall equipment structure by eliminating the need for complex integrated pressing mechanisms.
Solution Approach 2:
The pressing mechanism is extracted from the tooling itself and implemented as a separate, movable plunger that can be independently actuated. This extraction simplifies the tooling structure by removing complex integrated pressing systems while maintaining compaction capability through the standalone plunger mechanism.
2Manufacturing precision
If conventional press methods are used, then compaction can be achieved, but the application of pressure is imprecise and cumbersome
Solution Approach 1:
The compaction system applies pressure locally and selectively to specific regions of the composite component through the movable plunger. This allows precise control over which areas are compacted and to what degree, enabling differential compaction strategies tailored to local requirements rather than uniform pressing across the entire component.
Solution Approach 2:
The plunger is designed to be movable rather than fixed, allowing dynamic adjustment of the compaction force and positioning. This dynamic capability enables precise control over pressure application timing, magnitude, and location, improving both precision and operational flexibility.
3Productivity
If conventional debulk methods are used, then composite components can be compacted, but the process time increases and efficiency decreases
Solution Approach 1:
The laminate is pre-positioned and secured to the stationary tool before the compaction process begins. This preliminary setup ensures proper alignment and prevents movement during pressing, eliminating time losses associated with repositioning or correcting misaligned components during the compaction process.
Solution Approach 2:
The movable plunger enables rapid application and removal of compaction force in a single swift operation. This approach skips the need for gradual, multi-stage pressing sequences, reducing the overall compaction cycle time while achieving the required density and consolidation in one efficient action.
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 system enables precise, efficient compaction with minimal equipment, reducing process time and improving part yield by allowing targeted pressure application and controlled displacement.
Implementation Method 1
moving a plunger to apply a force on the noodle ring so that the noodle ring compacts the noodle into the cavity
Data Source
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AI summary
Compaction systems and methods of compacting components are provided. In one aspect, a laminate of a component can be laid up on a tool of a compaction system. The laminate defines a cavity. A noodle is positioned relative to or in the cavity. A noodle ring is then positioned relative to the noodle. For instance, the noodle ring can be placed over the noodle. A cross section of the noodle ring can be shaped complementary to a cross section of the noodle. A plunger of the compaction system is moved so that it engages the noodle ring. Particularly, the plunger is moved in such a way that a force is applied on the noodle ring so that the noodle ring compacts the noodle into the cavity.