Composite Profile Coating for Complex Non-Developable Shapes
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Solution Overview
Problem
Existing methods for manufacturing profiled elements with pigmented coatings face challenges in reducing manufacturing time and flexibility, particularly when dealing with non-developable geometries and complex shapes.
Innovation Solution
The use of a knitted structure as a support for a pigmented film, which is applied flat and cured/deformed simultaneously with the preform, allowing the film to adapt to non-developable geometries and complex shapes, thereby reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pigmented coating is applied to the profiled element after hardening, then the surface appearance and wave beam absorption are improved, but the manufacturing time is significantly increased due to long drying time
Solution Approach 1:
The patent combines the pigmented layer application with the preform shaping step by applying the pigmented layer to the flat preform before deformation. This allows the pigmented layer to be formed and deformed simultaneously with the structural plies, eliminating the need for a separate post-hardening coating step and reducing manufacturing time
Solution Approach 2:
The pigmented layer is applied to the flat preform before the deformation step, allowing it to be positioned and prepared in advance. This preliminary application enables the pigmented layer to be deformed together with the preform structure during the subsequent shaping operation, rather than requiring separate post-processing
2Loss of time
If a pigmented layer is placed on the flat preform before deformation, then the manufacturing time is reduced, but it is difficult to handle the thin pigmented film without damaging it
Solution Approach 1:
The patent employs a flexible backing structure that supports the thin pigmented film during handling and deformation. This backing structure provides mechanical strength to protect the fragile pigmented film while allowing it to conform to the deformed preform geometry, making the thin film manageable throughout the manufacturing process
3Reliability
If the pigmented layer is applied to achieve coverage on complex geometries, then the surface coverage is improved, but the deformation process becomes more complex
Solution Approach 1:
The patent merges the deformation of the preform structure with the deformation of the pigmented layer by applying the layer before shaping. This coordinated deformation ensures the pigmented layer conforms to complex geometries including non-developable surfaces without requiring separate deformation steps or complex additional equipment
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 enables the production of profiled elements with complex geometries in a more efficient manner by shortening the manufacturing process and ensuring the pigmented layer adheres well to non-developable surfaces.
Implementation Method 1
promoting the absorption of the wave beam
Data Source
AI summary
A method for manufacturing a profiled element made of composite material including a step of obtaining a preform and a step of placing at least one pigmented layer on the preform, the pigmented layer including at least one pigmented film and at least one support structure having a knitted structure. Because the knitted structure is flexible, it is possible to obtain profiled elements with complex geometries. A profiled element obtained from such a method and a stiffened panel comprising at least one such profiled element are also provided.