Composite Radius Filler Forming via Strip Separation
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Solution Overview
Problem
Traditional methods for forming radius fillers for composite structures lack tight control over shape and are labor-intensive, often resulting in voids and mechanical instability in composite structures during curing.
Innovation Solution
A system and method involving a sheet-locating structure, separation device, and layup surface to form strips of composite material, which are then compacted and stacked to create a radius filler with precise shape and mechanical support, using a conveyance structure to translate and separate the sheet into strips with controlled width and location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional radius fillers utilize a single length of composite material that is creased and molded, then the manufacturing process is simpler, but the shape control is loose and labor intensity is high
Solution Approach 1:
The composite material sheet is divided into multiple parallel strips through automated separation, with each strip contributing to a specific portion of the radius filler shape. This segmentation enables precise control of the final shape while maintaining manufacturing efficiency through continuous processing.
Solution Approach 2:
The strips are separated and positioned in advance on the layup surface before the molding process begins. This preliminary arrangement of strips allows for precise shape control to be established before curing, eliminating the need for post-shaping adjustments.
2Adaptability or versatility
If traditional radius fillers utilize manually stacked composite material lengths, then shape adjustment is possible, but the process is labor-intensive and productivity is low
Solution Approach 1:
Manual stacking operations are replaced with an automated separation device that mechanically divides the composite sheet into multiple strips and conveys them to the layup surface. This substitution eliminates labor-intensive manual handling while maintaining the ability to adjust strip configuration for different shapes.
Solution Approach 2:
The system allows dynamic adjustment of the number of strips, their spacing, and their positions on the layup surface. This dynamic configurability enables versatile shape adaptation while the automated process maintains high productivity through continuous operation.
3Ease of manufacture
If radius fillers are formed with loose shape control, then manufacturing is easier, but voids and distortion occur during composite structure curing
Solution Approach 1:
The automated separation and conveyance system provides precise control over strip positioning and spacing, ensuring that the radius filler maintains its intended shape throughout the curing process. This precision feedback control eliminates voids and distortion that would otherwise compromise structural integrity.
Solution Approach 2:
The precise shape of the radius filler is established in advance through automated strip arrangement before the composite structure begins curing. This preliminary precision shaping ensures that no voids or distortions develop during the curing process, guaranteeing structural integrity.
4Manufacturing precision
If automated strip separation and conveyance is implemented, then shape precision and productivity improve, but device complexity increases
Solution Approach 1:
The separation device is designed to perform multiple functions: dividing the composite sheet into strips, conveying the strips to the layup surface, and enabling positional adjustments. This multi-functionality reduces the need for separate devices for each operation, thereby limiting the increase in overall system complexity.
Data Source
AI summary
Methods for forming radius fillers for composite structures are disclosed herein. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include supporting the second portion of the sheet with a second support surface and separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface.