Composite Stiffened Panel Manufacturing via Sub-Panel Merging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing stiffened structural components using composite materials are laborious, costly, and inefficient, particularly due to the complexity of spindle preparation, manual fixing of ribs, and the need for joining elements that increase weight and stress zones.
Innovation Solution
A method involving the creation of sub-panels with pre-cured stringers and ribs fixed to a sub-skin, which are then joined together to form a pre-component. This pre-component serves as a tool for laminating additional composite layers to form a continuous external over-skin, eliminating the need for a shaped spindle and reducing production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a shaped spindle is used for manufacturing stiffened structural components, then the structural integrity and shape accuracy are improved, but the device complexity and production time increase significantly
Solution Approach 1:
The structural component is divided into multiple sub-panels that are manufactured separately and then joined together. Each sub-panel contains a subset of stringers and ribs, allowing parallel production without requiring a complex shaped spindle for the entire structure.
Solution Approach 2:
Stringers and ribs are pre-cured separately before being assembled to the skin panels. This preliminary curing action allows these stiffening elements to be manufactured independently and then integrated, eliminating the need for complex spindle preparation during final assembly.
2Manufacturing precision
If manual fixing of ribs is performed, then the positioning precision is improved, but the productivity decreases
Solution Approach 1:
Ribs are pre-positioned and pre-cured on the skin panels during the sub-panel manufacturing stage. This preliminary action allows precise positioning to be achieved once, during sub-panel fabrication, rather than requiring repeated manual adjustments during final assembly.
Solution Approach 2:
The manufacturing process merges multiple operations into the sub-panel fabrication stage: skin lamination, rib positioning, rib curing, and stringer attachment all occur together during sub-panel production. This integration eliminates separate manual fixing operations later.
3Reliability
If joining elements are used to assemble sub-panels, then the structural reliability is improved, but the weight increases
Solution Approach 1:
Multiple sub-panels are joined together using adhesive bonding to form a single integrated skin structure. This merging approach eliminates the need for mechanical joining elements such as rivets or bolts, thereby reducing weight while maintaining structural reliability through continuous adhesive bonds.
Solution Approach 2:
The joining process uses composite-compatible adhesives that bond the sub-panels together to form an integrated structure. The adhesive bonds create a composite-like continuous structure that distributes stresses effectively without requiring heavy metal fasteners.
4Strength
If joining elements are used to connect sub-panels, then the connection strength is improved, but stress concentrations and harmful factors increase
Solution Approach 1:
Sub-panels are joined using adhesive bonding that creates a continuous, smooth transition between panels. This merging approach eliminates discrete joining elements that would create stress concentrations, resulting in a more uniform stress distribution across the entire skin structure.
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
The method significantly reduces production time and costs, enhances resistance to stresses, and eliminates the need for heavy joining elements, resulting in a lightweight, reliable, and cost-effective structural component.
Implementation Method 1
applying a pre-set temperature and pressure so as to cure the composite material and determine the rigid and integral fixing of the stringer and of the rib to the second surface of the sub-skin
Implementation Method 2
laminating first layers of non-cured composite material on a forming tool thus forming a sub-skin
Data Source
AI summary
A method for manufacturing a structural component is disclosed. The structural component comprises a skin formed by layers of composite material, stringers made of a composite material fixed to the skin and ribs made of a composite material fixed to the skin, the structural component has sub-panels joined to one another and each comprising a sub-skin defined by first layers of composite material, at least one stringer and at least one rib fixed to an internal surface of the sub-skin, wherein the structural component comprises a continuous sub-wall defined by the union of the external surfaces of the sub-skins of the sub-panels joined to one another, second layers of composite material are laminated on the first layers so as to define a continuous external over-skin layered on said sub-wall, wherein the skin is defined by the set of said sub-skins and over-skins and consists of the first and second layers.