Composite Panel Rib Intersections Continuous Fiber Reinforcement
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Solution Overview
Problem
Existing methods for manufacturing composite structures, such as those used in aircraft, via press-forming lack adequate reinforcement at intersecting portions of ribs, relying primarily on matrix resin for strength, which is insufficient.
Innovation Solution
A composite panel structure with ribs intersecting on a substrate, where continuous or slit continuous fibers are arranged at both the ribs and their intersecting portions, achieved through laminating prepregs and subjecting them to press-forming with a molding die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If press-forming is used to manufacture composite structures, then productivity is improved and mass production becomes feasible, but the strength at rib intersecting portions deteriorates because only matrix resin is present without reinforced fibers
Solution Approach 1:
The manufacturing process is segmented into distinct steps: first forming the substrate portion, then separately forming the rib portion by laminating prepregs with reinforced fibers at the rib location before final press-forming. This segmentation allows reinforced fibers to be strategically placed at rib intersecting portions while maintaining the efficiency of press-forming for mass production.
Solution Approach 2:
Reinforced fibers are locally applied only at the rib intersecting portions where strength is critical, rather than uniformly throughout the entire composite structure. The prepregs are laminated specifically at the rib location before press-forming, providing localized reinforcement that improves strength at critical areas while maintaining overall productivity.
2Strength
If autoclave molding is used to manufacture composite structures, then the strength and quality of composite parts is improved, but the molding time increases making it unsuitable for mass production
Solution Approach 1:
The rib portion is preliminarily formed by laminating prepregs with reinforced fibers at the rib location before the final press-forming process. This preliminary action ensures that reinforced fibers are already in place at critical rib intersecting portions before molding, achieving high strength without requiring the lengthy autoclave molding process.
Solution Approach 2:
The invention changes the manufacturing parameters from traditional autoclave molding to a modified press-forming process with preliminary preping lamination. This parameter change reduces molding time significantly while maintaining or improving strength through the strategic placement of reinforced fibers in the prepregs at rib locations.
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 enhances the strength and rigidity of the intersecting portions by ensuring continuous fibers are present, improving the structural integrity of the composite panel.
Implementation Method 1
subjecting the substrate material portion and the additional lamination portion to press-forming with a molding die
Implementation Method 2
subjecting the substrate material portion and the additional lamination portion to press-forming with a molding die
Data Source
AI summary
A panel structure (10A) includes a substrate portion (11) and at least two ribs (12) standing on the substrate portion (11) and intersecting with each other. A substrate material portion (24) constituting the substrate portion (11) is formed by using at least matrix resin. Continuous fibers or slit continuous fibers are arranged at a position corresponding to the ribs (12) and a rib intersecting portion (13).