Composite Preform Curing via Heated Tool and Inflatable Bladder
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Solution Overview
Problem
Current methods for manufacturing composite aircraft components are resource-intensive and time-consuming, particularly due to the lengthy cure cycles required for composite barrel sections, which tie up resources and limit production efficiency.
Innovation Solution
A system and method that utilizes a tooling assembly with a heating element and a mandrel featuring a bladder assembly with a shape memory layer, allowing for the quick curing of composite preforms by heating the outer mold line surface and inflating the bladder to compress the preform, enabling the extraction of the gelled composite in a shorter time frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional autoclave curing process is used, then composite structures are successfully manufactured, but cycle time is excessively long (4 to 24 hours) and resource utilization is poor
Solution Approach 1:
The patent changes the temperature parameter by heating the tool to a processing temperature (e.g., 80°C to 100°C) before placing the composite preform, and uses a bladder assembly to apply controlled pressure. These parameter changes enable the resin to gel rapidly in 5 to 30 minutes instead of requiring 4 to 24 hours in a traditional autoclave, dramatically reducing cycle time while maintaining cure quality
Solution Approach 2:
The patent performs preliminary heating of the tool to processing temperature before the composite preform is placed in the tool. This preliminary action ensures that when the preform is added, the resin immediately begins to gel at the optimal temperature, eliminating the long wait time required in traditional autoclave processes and enabling rapid production cycles
2Productivity
If fixed tooling with manual vacuum bagging is used, then composite structures are manufactured, but resource utilization is excessive and process complexity is high
Solution Approach 1:
The patent extracts and eliminates the need for vacuum bags, caul plates, and complex autoclave equipment by using a bladder assembly that can be directly placed in a simple heated tool. This extraction of unnecessary components simplifies the manufacturing process, reduces resource consumption, and maintains manufacturing capability
Solution Approach 2:
The bladder assembly is designed to be manually inflatable and self-contained, eliminating the need for complex vacuum systems, autoclave equipment, and extensive manual labor for applying vacuum bags and caul plates. The system serves itself through simple inflation of the bladder to apply the necessary compression pressure
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 resource utilization and cycle time, allowing for faster production of composite structures using quick cure resins that cure in under 30 minutes, thereby enhancing manufacturing efficiency and reducing costs associated with traditional autoclave processes.
Implementation Method 1
heating an outer mold line surface of a tool to a processing temperature
Implementation Method 2
The consolidated layup is then placed into an autoclave for heating and compressing until cured
Implementation Method 3
the bladder assembly has a shape memory layer and a bladder
Data Source
AI summary
A system and method of forming a composite structure includes heating an outer mold line surface of a tool to a processing temperature, positioning an inner mold line surface with a composite preform disposed thereon within the outer mold line surface, and extracting the inner mold line surface and the composite preform in a gelled state from the outer mold line surface.