Composite Panel Bends via Curved Slot Geometry
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Solution Overview
Problem
Current methods for forming bends in composite panels are time-consuming, labor-intensive, and often result in voids that require additional filler material, increasing weight and complexity.
Innovation Solution
A method involving the formation of a slot with unique geometry that closes upon bending, providing continuous support and eliminating voids, allowing for a solid joint without the need for fillers, by creating a slot with inclined surfaces and curved flanges that conformally engage the panel's facesheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a slot is formed by removing a strip of material from the panel, then the panel can be bent to the required angle, but voids remain in the slot requiring filler material
Solution Approach 1:
The slot is designed with curved flanges that match the bend radius, allowing the slot to close smoothly during bending without creating voids. The curved geometry enables the material to flow and conform to the bend shape, eliminating the need for filler material while maintaining joint solidity.
Solution Approach 2:
The slot geometry parameters are specifically designed with curved flanges having a radius equal to the desired bend radius. This parameter change from a traditional rectangular slot allows the slot to close properly during bending, eliminating voids and eliminating the need for additional filler material.
2Stability of the object's composition
If traditional molding techniques are used to form bends, then the bend becomes permanently set, but the process is time consuming and labor intensive
Solution Approach 1:
The slot with curved flanges is pre-formed in the panel before bending. This preliminary preparation allows the panel to be bent efficiently without requiring time-consuming molding processes. The curved flanges are already in place to guide the bending process and ensure proper form, eliminating the need for separate molding steps.
Solution Approach 2:
The curved flanges are designed to self-align and self-support during the bending process. As the panel is bent, the curved flanges automatically conform to the bend radius and provide continuous support, eliminating the need for external molding tools or complex fixture systems.
3Reliability
If filler material is used to fill voids in the slot, then a solid joint is achieved, but weight increases and additional waiting time is required
Solution Approach 1:
The curved flanges eliminate the need for filler material by allowing the slot to close smoothly during bending. The curved geometry enables the panel edges to meet and form a solid joint without voids, thereby eliminating the need to add weight with filler material while maintaining joint solidity.
4Reliability
If the slot geometry is optimized to close upon bending, then voids are eliminated, but the slot requires precise geometric features
Solution Approach 1:
The curved flanges with radius equal to the bend radius provide a simple yet effective geometric solution. This single curvature parameter enables the slot to close properly during bending, eliminating voids without requiring complex multi-parameter geometries or multiple processing steps.
Data Source
AI summary
A composite panel with a bend therein is formed by first and second adjacent panel sections having a common facesheet forming an outer radius of the bend, and a substantially void-free joint between the adjacent panel sections.