Composite Panel Frame for Trimming-Free Curing
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Solution Overview
Problem
The manual lay-up and curing of composite fiber plies for complex contoured structures in aircraft and vehicles is labor-intensive and prone to errors, leading to inconsistencies and increased manufacturing costs due to the need for extensive hand labor, trimming, and sealing processes.
Innovation Solution
A method and system that uses a frame with an outer mold line surface and edges to support uncured plies during curing, ensuring the final size and shape of the composite panel is achieved without trimming, and incorporates a windswept surface for aerodynamic performance and reduced sealing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual lay-up of pre-preg plies is used, then complex contoured composite structures can be formed, but the process becomes time-consuming and laborious
Solution Approach 1:
The patent applies preliminary action by pre-assembling the composite plies into a complete panel structure before curing. The entire composite panel is constructed with all plies, fasteners, and structural elements in their final positions while uncured, allowing the curing process to lock everything in place simultaneously. This eliminates the need for post-cure trimming and assembly operations, significantly reducing labor time while maintaining the ability to form complex contoured structures.
2Ease of manufacture
If plies are placed on mandrel by hand, then the structure can be formed, but engineering tolerances become very loose due to difficulty of placing plies
Solution Approach 1:
The patent uses the uncured state of the composite plies as an intermediary condition that enables precise positioning. Because the plies are flexible and uncured during assembly, they can be easily manipulated and positioned with high precision relative to the mandrel features. Once cured, the plies lock into their precise positions. This intermediary uncured state acts as a facilitator for achieving tight tolerances that would be difficult to obtain with cured materials.
3Manufacturing precision
If cured composite fibers are trimmed to final size, then the specified shape and size are achieved, but the process is time-consuming and laborious
Solution Approach 1:
The patent applies preliminary action by defining the exact final boundaries of the composite panel using the mandrel's physical features before curing. The mandrel includes precise edge features and surface geometry that directly determine the final panel dimensions. The composite plies are positioned to extend exactly to these boundary features while uncured, so that after curing, the panel naturally achieves its final specified shape and size without requiring any trimming operations.
4Manufacturing precision
If equipment is used to trim cured composite fibers, then the final shape and size are achieved, but expensive equipment and considerable manufacturing cost are introduced
Solution Approach 1:
The patent eliminates the need for expensive trimming equipment by performing the dimensional definition action preliminarily, before curing. The mandrel's precise geometry and the positioning of uncured plies establish the final panel dimensions in advance. The curing process simply locks in these pre-established dimensions, transforming a complex post-cure trimming operation into a simple pre-cure positioning operation that requires no specialized equipment.
5Manufacturing precision
If manual trimming is used, then the final shape is achieved, but process variations lead to undesired inconsistencies
Solution Approach 1:
The patent applies self-service by designing the mandrel and composite positioning system to automatically ensure consistent final dimensions without human intervention. The mandrel's physical features, such as edge profiles and surface geometry, directly define the panel boundaries, and the uncured composite plies naturally conform to these features. This self-defining system eliminates variability introduced by manual trimming operations, ensuring that every panel produced achieves the same precise dimensions through the inherent geometry of the tooling rather than operator skill.
6Object-affected harmful factors
If cured composite fibers are sealed after curing, then protection from elements is achieved, but the process is time-consuming and laborious
Solution Approach 1:
The patent applies preliminary action by incorporating sealing features directly into the mandrel and composite structure before curing. The mandrel includes integrated sealing surfaces and the composite plies are positioned to create self-sealing joints while uncured. After curing, the structure already possesses inherent sealing capabilities through its geometry and joint design, eliminating or minimizing the need for separate post-cure sealing operations.
7Object-affected harmful factors
If manual sealing of gaps between panels is used, then gaps are filled with sealant, but the process is time-consuming and introduces process variations
Solution Approach 1:
The patent applies asymmetry by designing complementary asymmetric features on adjacent panels that create tight, self-aligning joints. The panel edges include asymmetric profiles such as male-female connections or interlocking geometries that naturally mate together with minimal gap formation. This asymmetric design eliminates the need for manual sealant application by creating joints that are inherently tight and weather-resistant through their geometric complementarity.
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 approach reduces manufacturing time and costs by eliminating the need for post-cure trimming and sealing, while ensuring precise dimensions and aerodynamic performance through the use of a frame that supports the plies during curing, resulting in consistent and efficient composite panel production.
Implementation Method 1
The OML inner surface and the edge inner surface support the uncured plies during a curing process
Implementation Method 2
curing the uncured plies using a curing process
Data Source
AI summary
A method of manufacturing a composite panel for an air vehicle having a predetermined size and shape. The method includes forming a frame including an outer mold line surface and at least one edge extending from the outer mold line surface. The outer mold line surface includes an OML inner surface. The edge includes an edge inner surface and an edge outer surface opposite the edge inner surface. The OML inner surface and the edge inner surface define a cavity. The method also includes positioning a plurality of uncured plies within the cavity. The OML inner surface and the edge inner surface support the uncured plies during a curing process. The method further includes curing the uncured plies using the curing process. A post-cure size and shape of the cured plies and the frame corresponds to the predetermined size and shape without trimming any of the cured plies.