Composite Stiffened Panel Manufacturing Without Caul Plate
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Solution Overview
Problem
The existing method for manufacturing stiffened panels using composite materials is complex and requires a long installation time for the polymerization or consolidation tool, and it also necessitates a significant cleaning phase due to the use of a caul plate.
Innovation Solution
The method involves laying the skin on a mold with the second face pressed against the laying surface, and then positioning the mandrels on the skin, eliminating the need for a caul plate and simplifying the sealing barrier, thereby reducing installation time and cleaning requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a caul plate is used in the polymerization or consolidation tool, then the surface finish on the second face is improved, but the cleaning phase becomes significant and time-consuming
Solution Approach 1:
The invention removes the caul plate from the polymerization or consolidation tool, extracting the element that causes cleaning difficulties while maintaining surface finish quality through alternative means
Solution Approach 2:
The invention uses a disposable sealing barrier that is discarded after use, eliminating the need for cleaning and reducing time loss, while maintaining the required surface finish quality
2Reliability
If a complex polymerization or consolidation tool is used, then the manufacturing process is complete, but the installation time becomes relatively long
Solution Approach 1:
The invention divides the sealing function into separate components (sealing barrier and mold integration), making each component simpler and easier to install while maintaining overall process reliability
Solution Approach 2:
The invention extracts and removes the caul plate from the tool assembly, simplifying the overall structure and reducing installation time while maintaining manufacturing completeness through alternative sealing arrangements
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 simplifies the manufacturing process by eliminating the need for a caul plate and reducing the complexity of the sealing barrier, resulting in shorter installation times and reduced cleaning efforts while maintaining a satisfactory surface finish.
Implementation Method 1
a polymerization or consolidation step
Implementation Method 2
a polymerization or consolidation step
Implementation Method 3
the flanges of the profiles being pressed together in pairs
Implementation Method 4
a sealing barrier designed to form, with at least the mold, a substantially sealed enclosure
Data Source
AI summary
A method for manufacturing a stiffened panel, obtained from profiles and a skin, comprising a step of obtaining the profiles and of positioning each of the profiles on a mandrel, a step of laying the skin on a laying surface of a mold and then a step of laying the mandrels on the skin, the bases of the profiles being positioned against the skin, as well as a step of polymerizing or consolidating the profiles and the skin to obtain a stiffened panel. Also a tool for implementing such a method.