Composite Processing Apparatus with Sealed Vessel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional autoclave and oven processing techniques for large composite structures, such as aircraft components, are inefficient due to high costs, long cycle times, and the need for significant space and consumable materials.
Innovation Solution
A processing apparatus that uses a mandrel-tool and tooling assembly to form a sealed vessel, applying pressure and heat, reducing the volume of gas required and eliminating the need for consumable materials like bagging, while allowing for automatic movement and reconfiguration to process composite structures efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional autoclave and oven processing techniques are used for large composite structures, then the composite structures can be processed, but the floor space required increases significantly
Solution Approach 1:
The processing system is divided into a mobile processing cart that can be positioned within the autoclave, separating the processing function from the stationary autoclave structure. This allows the processing apparatus to be compact and movable, reducing the floor space footprint while maintaining full processing capability for large composite structures
Solution Approach 2:
The processing cart is designed to be nested within the autoclave chamber during operation. The cart contains all necessary processing components (heating elements, pressure systems, vacuum hoses) that are typically external in conventional systems, allowing the entire processing system to be contained within the autoclave volume rather than requiring external equipment space
2Manufacturing precision
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but the cycle time increases due to heating and cooling requirements
Solution Approach 1:
The processing cart is pre-positioned within the autoclave with all processing components ready before the composite structure is loaded. Vacuum hoses, heating elements, and pressure systems are pre-configured and connected, eliminating the time required for manual installation and setup between processing cycles
Solution Approach 2:
The processing cart is designed with self-contained heating, cooling, and vacuum systems that can operate independently within the autoclave. The system includes integrated temperature sensors and control mechanisms that automatically manage the processing parameters, reducing the need for external intervention and minimizing cycle time
3Manufacturing precision
If conventional processing techniques are used, then composite structures can be processed, but manual installation and removal of vacuum hoses and temperature sensors is required, increasing cycle time
Solution Approach 1:
The processing cart incorporates fixed, pre-positioned vacuum hose connections and temperature sensor mounts that remain in place throughout multiple processing cycles. The system automatically connects and disconnects these components through integrated mechanisms, eliminating manual installation and removal operations and significantly improving processing throughput
Solution Approach 2:
The processing cart serves as an intermediary platform between the autoclave environment and the composite structure. It provides standardized, reusable connection points for vacuum hoses and temperature sensors, allowing rapid attachment and detachment without manual configuration, thereby increasing productivity
4Manufacturing precision
If conventional processing techniques are used, then composite structures can be processed, but consumable materials such as bagging are required, increasing cost
Solution Approach 1:
The processing cart provides a reusable, rigid processing environment that eliminates the need for disposable bagging materials. The cart's structured design with integrated sealing and support mechanisms allows direct processing of composite structures without consumable coverings, reducing material waste and processing costs
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 solution reduces processing costs, cycle times, and facility space requirements, while increasing throughput and flexibility in composite processing, by using the mandrel-tool to support the composite structure and form part of the processing vessel.
Implementation Method 1
the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel, configured to apply at least one of pressure and heat to the composite structure
Implementation Method 2
the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel, configured to apply at least one of pressure and heat to the composite structure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of processing a composite structure includes a step of positioning a first processing tool of a tooling assembly and a second processing-tool of the tooling assembly from an open position, in which the first processing-tool and the second processing-tool are spaced apart, to a closed position, in which the first processing-tool and the second processing-tool are sealed to each other and are sealed to a mandrel-tool (1008), supporting the composite structure, to form a vessel (1010) that surrounds the composite structure. The method also includes a step of processing the composite structure (1012).