Composite Skin Assembly Using Flexible Substrate and Deformation
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Solution Overview
Problem
The construction and assembly of large and complex composite structures, such as airplane fuselage barrels, are time-consuming and costly due to the serial process of forming support structures and applying composite fibers around a layup mandrel.
Innovation Solution
A system and method utilizing a flexible substrate to support a charge of composite material, where the composite-substrate assembly is pressed against the layup mandrel to deform and affix the material, allowing for efficient assembly by releasing the material from the substrate while retaining it on the mandrel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a serial process is used to form support structures and apply composite fibers sequentially on a layup mandrel, then each layer can be applied individually with precision, but the assembly time becomes significant and costs increase for large and complex composite structures
Solution Approach 1:
The support structures (stringers and spacers) are pre-formed and pre-positioned on the layup mandrel before the composite skin is applied. This preliminary preparation allows the composite fibers to be wrapped continuously around the pre-assembled support structures, eliminating the need to apply each support structure layer by layer during the main assembly process, thereby significantly reducing assembly time while maintaining precision
Solution Approach 2:
The patent implements a continuous wrapping process where composite fibers are applied continuously around the layup mandrel that already contains pre-positioned support structures. This continuous action replaces the serial, step-by-step application method, maintaining manufacturing precision while dramatically improving productivity by eliminating interruptions and repositioning operations
2Manufacturing precision
If support structures are formed from multiple plies applied individually and sequentially, then each ply can be precisely positioned, but the time required to complete the structure increases significantly
Solution Approach 1:
Multiple plies of composite material are pre-assembled into complete support structures (stringers and spacers) before being placed on the layup mandrel. This preliminary assembly of multiple plies into finished components allows for precise positioning to be achieved during the pre-fabrication stage, rather than requiring time-consuming sequential application during final assembly
Solution Approach 2:
The composite structure is divided into distinct functional segments: pre-formed support structures (stringers and spacers) and the continuous composite skin. This segmentation allows the support structures to be manufactured and positioned separately with high precision, while the skin is applied continuously, reducing overall construction time by parallelizing these operations
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 assembly time and costs by enabling faster and more efficient deformation and affixation of composite materials to the mandrel, improving the process for large and complex composite structure construction.
Implementation Method 1
applying a retention vacuum between the charge of composite material and the flexible substrate
Implementation Method 2
pressing the composite-substrate assembly against an outer surface of the layup mandrel to deform the composite-substrate assembly to a final conformation
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 and locating the composite-substrate assembly and a layup mandrel proximal to one another. The methods further include pressing the composite-substrate assembly against an outer surface of the layup mandrel to deform the composite-substrate assembly to a final conformation. The methods also include affixing the charge of composite material to the outer surface of the 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, the layup mandrel, and an assembly deformation structure that is configured to press the composite-substrate assembly against the outer surface of the layup mandrel.