Composite Panel Edge Wrapping Automation

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Solution Overview

Problem

The existing manual edge wrapping process for composite panels is time and labor intensive, ergonomically awkward, and not amenable to automation, making it inefficient and costly.

Innovation Solution

A method of forming composite panels that involves providing an initial composite material, heating it, molding it to form a preliminary panel with a main body and an outer edge, securing a laminate layer to the outer edge, and folding the exterior edge portion over the interior edge portion to create an external folded edge with the laminate layer on its surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual edge wrapping process is used, then edge coverage is achieved, but production time and labor cost increase significantly

Engineering Contradiction:

Improveedge wrapping processVSAvoidproduction time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The laminate is pre-positioned on the molding tool before the composite panel is formed. This preliminary placement allows the laminate to be automatically integrated into the panel during the molding process, eliminating subsequent manual wrapping operations and significantly reducing production time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The edge wrapping function is merged with the primary molding process. By integrating laminate application and panel formation into a single automated molding operation, the patent eliminates the need for separate manual wrapping steps, thereby improving productivity while maintaining manufacturing quality.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If manual edge wrapping is performed, then decorative laminate is applied, but the process is ergonomically awkward and labor intensive

Engineering Contradiction:

Improvelaminate applicationVSAvoidergonomic conditions

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The molding process itself performs the laminate application function. The heated composite material automatically conforms to the molding tool including the pre-positioned laminate, making the system self-sufficient and eliminating the need for manual handling that creates ergonomic problems.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical wrapping operations are replaced with an automated thermal-mechanical molding process. The heat and pressure applied during molding automatically bond the laminate to the panel edges, substituting ergonomic-intensive manual labor with an automated physical-chemical process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If separate vacuum forming process is used after curing, then laminate is applied, but additional process steps increase production time

Engineering Contradiction:

Improvelaminate application processVSAvoidproduction cycle time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent merges the laminate application process with the primary curing/molding operation. By positioning the laminate on the mold before material placement, both the structural panel formation and decorative laminate bonding occur in a single integrated process, eliminating the need for separate vacuum forming steps and reducing total production cycle time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The laminate is pre-positioned on the molding tool before the composite material is applied and cured. This preliminary placement ensures the laminate is ready for immediate integration during the molding process, eliminating subsequent separate application steps and reducing overall production time.

Inventive Principle:

Principle #10Preliminary 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

This method enables the efficient and automated coverage of peripheral edges of composite panels, reducing production time and cost while meeting FAA requirements for flammability, and producing high-quality, structurally sound composite panels with edge-wrapped decorative laminates.

Implementation Method 1

heating the initial composite material, molding the initial composite material to form a preliminary composite panel

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

folding an exterior edge portion of the outer edge over an interior edge portion to provide an external folded edge

Methodology Applied

Scientific EffectFolding: Folding

Implementation Method 3

said molding includes co-molding the preliminary composite panel along with the laminate layer

Methodology Applied

Scientific EffectCo-molding:

Data Source

PatentUS12325178B2Composite panels

Publication Date: 2025.06.10 THE BOEING CO

AI summary

A method of forming a composite panel includes providing an initial composite material, heating the initial composite material, molding the initial composite material to form a preliminary composite panel having a main body connected to an outer edge and a laminate layer secured to the outer edge, and folding an exterior edge portion of the outer edge over an interior edge portion to provide an external folded edge having the laminate layer on at least a portion of an outer surface.