Composite Plank Support for Stringer Panel Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing aircraft stringer panels face challenges such as distortions, resin bleeding, cracking, and wrinkles due to imperfections in support structures, requiring additional labor, materials, and extensive tooling, which are costly and labor-intensive, and result in inefficient use of factory space.
Innovation Solution
The use of a composite plank with layered laminate plies, pre-impregnated with resin and oriented in different directions, which is co-cured with the stringer and skin member, providing a stable and precise support structure that eliminates the need for flimsy noodles, reducing voids and imperfections, and is supported by a silicon forming mandrel with silica micro-balloons for uniform expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional support structures (noodles) are used during manufacturing, then the process is simpler, but manufacturing precision deteriorates due to distortions, resin bleeding, cracking, and wrinkles
Solution Approach 1:
The support structure is divided into multiple discrete planks (first plank, second plank, third plank) positioned at different locations along the stringer. Each plank is a separate component that can be independently manufactured and positioned, allowing for precise control of support in different regions while maintaining overall structural integrity
Solution Approach 2:
The planks are constructed from composite materials (carbon fiber reinforced polymer) that provide high strength and stiffness to withstand manufacturing loads without deforming. This composite construction enables the support structure to maintain geometric precision under the stresses of panel formation, curing, and handling
2Manufacturing precision
If extensive tooling and forming equipment are used, then manufacturing precision improves, but loss of substance increases due to material handling requirements and factory space needs
Solution Approach 1:
The planks are designed to be self-supporting structures that maintain the geometric integrity of the stringer panel without requiring additional external tooling or forming equipment. The planks themselves serve as the support structure, eliminating the need for separate mandrels or fixtures, thereby reducing material handling requirements and factory space needs
3Reliability
If traditional support structures are used, then device complexity is reduced, but reliability deteriorates due to imperfections requiring additional labor and materials for repair
Solution Approach 1:
The planks are pre-positioned and secured to the stringer panel before the curing process begins. This preliminary action ensures that the support structure is firmly in place to prevent any movement or deformation during manufacturing, eliminating the need for post-manufacturing repairs and ensuring high reliability of the final product
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 structural integrity and geometry of the panel assembly, reduces manufacturing challenges, and minimizes labor and material costs by providing a stronger, more stable support that maintains uniform pressure and reduces resin bleeding and ply wrinkles, resulting in improved panel quality and efficiency.
Implementation Method 1
a silicon forming mandrel comprising 20% silica micro-balloons mixed uniformly therein
Data Source
AI summary
Provided are methods of forming stiffened stringer panels with integrated plank structures. A skin member having an inner surface is provided. A plank is positioned onto the inner surface of the skin member. The plank extends from a first side to a second side, and each laminate ply of the set of layered laminate plies is sized to form a geometric profile for each of the first side and the second side. Each laminate ply of the set of layered laminate plies is arranged to extend from the first side to the second side. A stringer is placed onto a support tool. The support tool, and the stringer thereon, is positioned upon an uppermost laminate ply of the set of layered laminate plies. The skin member, the plank, and the stringer are joined.