Reinforced Composite Panel Groove Caul Sheet Manufacturing

Solution Overview

Problem

Composite material panels used in structural components, such as vehicles, are prone to buckling and moisture migration due to lack of proper support, leading to structural weakness and potential corrosion.

Innovation Solution

A method for manufacturing reinforced composite panels using a caul sheet with mirror-image grooves to create stiffening members, where composite material layers are folded and secured with nylon tubes and unidirectional plies, and cured under pressure to enhance rigidity and prevent separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If separate layers of composite material are used with honeycomb construction to reinforce the panel, then the panel stiffness is improved, but the panel becomes susceptible to separation between layers and honeycomb construction

Engineering Contradiction:

Improvepanel stiffnessVSAvoidlayer separation resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent merges the reinforcement layers with the honeycomb construction by positioning composite material layers directly on the honeycomb structure and curing them together. This integration eliminates the interface between separate layers and the honeycomb, preventing separation while maintaining the stiffening effect.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials consisting of multiple layers of composite material combined with the honeycomb construction. The layers are cured to form an integrated composite structure where the honeycomb and composite layers work together as a single unified reinforcement system, eliminating separation issues.

Inventive Principle:

Principle #40Composite materials

2Strength

If separate layers of composite material are used with honeycomb construction to reinforce the panel, then the panel stiffness is improved, but the panel becomes porous and susceptible to moisture migration

Engineering Contradiction:

Improvepanel stiffnessVSAvoidmoisture migration

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent merges the reinforcement layers with the honeycomb construction by positioning composite material layers directly on the honeycomb structure and curing them together. This integration eliminates the interface between separate layers and the honeycomb, preventing separation while maintaining the stiffening effect.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials consisting of multiple layers of composite material combined with the honeycomb construction. The layers are cured to form an integrated composite structure where the honeycomb and composite layers work together as a single unified reinforcement system, eliminating separation issues.

Inventive Principle:

Principle #40Composite materials

3Strength

If reinforcement material is positioned at a distance from the panel plane to resist transverse forces, then the panel resistance to buckling is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvebuckling resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming the honeycomb construction and pre-positioning the composite material layers on the honeycomb structure before final curing. This allows the reinforcement material to be positioned at the optimal distance from the panel plane to resist transverse forces while simplifying the overall manufacturing process through systematic preparation steps.

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

The method results in a rigid, non-porous, and cost-effective reinforced panel that effectively resists buckling and moisture migration, maintaining structural integrity and preventing corrosion.

Implementation Method 1

cured under pressure to enhance rigidity and prevent separation

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS9623610B2Method for manufacturing a reinforced panel of composite material

Publication Date: 2017.04.18 SPECTRUM AERONAUTICAL LLC

AI summary

A method for manufacturing rigid panels made of a composite material requires a caul sheet having a smooth surface that is formed with a plurality of grooves. A first layer of the composite material is laid on the caul sheet, and is cut to create flaps that extend into the respective grooves. Strips of composite material are then placed along the edges of the groove to extend and overlap each other in the groove. Next, a unidirectional ply is placed along the length of the groove, and this combination is then covered with a second layer of the composite material. Together, the combination of the first and second layers, the strips and the unidirectional ply are co-cured to create a rigid panel with integral stiffening members.