Composite Skin Assembly Using Flexible Substrate and Deformation
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Solution Overview
Problem
The assembly of large and complex composite structures is time-consuming and costly due to the serial process of forming support structures and applying composite fibers around a layup mandrel, necessitating improved systems and methods for assembling the skin of composite structures.
Innovation Solution
The use of a flexible substrate to support a charge of composite material, which is deformed from an initial to an intermediate conformation, then affixed to a layup mandrel, and released while retaining the material on the mandrel, utilizing retention and compaction vacuums to control the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a serial process is used to form support structures and apply composite fibers sequentially on a layup mandrel, then the composite structure can be assembled with traditional methods, but the assembly time becomes significant and cost increases for large and complex structures
Solution Approach 1:
The support structures are pre-formed on a removable core in a preliminary stage, allowing the composite skin to be applied as a complete assembly rather than building up layer by layer on the final mandrel. This preliminary preparation enables faster final assembly while maintaining structural integrity.
Solution Approach 2:
The manufacturing process is divided into separate segments: forming support structures on a removable core, applying the composite skin, and then removing the core. This segmentation allows parallel processing and eliminates the time-consuming sequential application of each layer on the final mandrel.
2Ease of manufacture
If traditional serial assembly methods are used for large composite structures, then the process follows established procedures, but the cost of layup mandrels and assembly time becomes substantial
Solution Approach 1:
A removable core acts as an intermediary tool that facilitates the formation of support structures during manufacturing but is discarded after use. This intermediary approach eliminates the need for expensive permanent layup mandrels while maintaining ease of manufacture through a modified but familiar process.
Solution Approach 2:
The removable core is discarded after serving its purpose of forming support structures, eliminating the need to invest in and maintain expensive permanent mandrels. This approach reduces equipment costs while improving assembly efficiency for large composite structures.
3Manufacturing precision
If composite fibers are applied layer by layer on a layup mandrel, then the skin can be formed with traditional layup techniques, but the time required becomes significant for large structures
Solution Approach 1:
The support structures are pre-formed with precise geometry on the removable core before the composite skin is applied. This preliminary precision work eliminates the need for time-consuming layer-by-layer adjustments during the final layup process.
Solution Approach 2:
The support structures and composite skin are merged into a single integrated assembly process. By combining these elements into one unified manufacturing step rather than separate sequential operations, the overall duration is reduced while maintaining manufacturing precision.
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 method reduces the time and cost associated with assembling composite structures by allowing for more efficient application and compaction of composite materials on the mandrel, improving the assembly process for large and complex structures.
Implementation Method 1
applying a retention vacuum between the charge of composite material and the flexible substrate
Implementation Method 2
applying a compaction vacuum between the flexible substrate and the outer surface of the layup mandrel with a compaction vacuum manifold that is defined by the flexible substrate
Data Source
AI summary
Systems and methods for assembling a skin of a composite structure are disclosed herein. The methods include operatively attaching a charge of composite material to a flexible substrate to define an initial conformation for a composite-substrate assembly, deforming the composite-substrate assembly to an intermediate conformation that is different from the initial conformation, affixing the charge of composite material to an outer surface of a layup mandrel, and releasing the charge of composite material from the flexible substrate while retaining the charge of composite material on the outer surface of the layup mandrel. The systems include the flexible substrate, an assembly deformation structure that is configured to deform the composite-substrate assembly from the initial conformation to the intermediate conformation, and the layup mandrel that receives the charge of composite material.