Composite Panel Edge Compression and Pre-applied Laminate

Solution Overview

Problem

The existing edge wrapping process for composite panels is manual, time-consuming, and ergonomically awkward, making it inefficient for automating the coverage of peripheral edges in composite panel systems, particularly in aircraft internal cabins.

Innovation Solution

A composite panel assembly system where a peripheral edge is compressed and rounded, using a core and pre-impregnated epoxy skins, with a decorative laminate applied, and a closeout spline to secure the edges, allowing for automated formation and aesthetically pleasing results.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a manual edge wrapping process is used to cover the peripheral edge of a composite panel, then the edge can be covered with a decorative laminate, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improveedge covering processVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The decorative laminate is pre-applied to the inner skin before the composite panel is assembled and cured. This preliminary action eliminates the need for post-assembly edge wrapping, significantly reducing manual labor and production time while maintaining aesthetic quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The edge covering function is merged into the main panel manufacturing process. The decorative laminate application is combined with the skin attachment process, so that edge coverage occurs automatically during panel fabrication rather than as a separate manual operation

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If a manual edge wrapping process is used to cover the peripheral edge of a composite panel, then the edge can be covered with a decorative laminate, but the process is ergonomically awkward

Engineering Contradiction:

Improveedge covering processVSAvoidergonomic conditions

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The decorative laminate is pre-applied to the inner skin before the composite panel is assembled and cured. This preliminary action eliminates the need for post-assembly edge wrapping, significantly reducing manual labor and production time while maintaining aesthetic quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing system performs the edge covering function automatically during panel fabrication. The processing equipment handles the laminate application and panel assembly without requiring manual edge wrapping operations, improving ergonomic conditions for workers

Inventive Principle:

Principle #25Self-service

3Reliability

If the peripheral edge is compressed and rounded to close the path into the core, then the edge is sealed and aesthetically pleasing, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveedge sealingVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The decorative laminate is pre-applied to the inner skin before the composite panel is assembled and cured. This preliminary action eliminates the need for post-assembly edge wrapping, significantly reducing manual labor and production time while maintaining aesthetic quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The edge covering function is merged into the main panel manufacturing process. The decorative laminate application is combined with the skin attachment process, so that edge coverage occurs automatically during panel fabrication rather than as a separate manual operation

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3730284B1Composite panel systems and methods

Publication Date: 2022.10.05 THE BOEING CO

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AI summary

A composite panel assembly and method of forming the same includes a core (102), an inner skin (104, 106) coupled to a first side (106) of the core (102) and an outer skin (108) coupled to a second side (110) of the core (102). A peripheral edge including portions of the core (102), the inner skin (104), and the outer skin (108), is compressed to close a path into the core.