Composite Stiffening Structure for Curved Thermoset Components
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Solution Overview
Problem
The existing methods for stiffening structural components made of thermosetting composite material, such as satellite antenna reflectors, are complex and time-consuming due to the need for numerous components and manual bonding operations, leading to high costs and inefficiencies.
Innovation Solution
A stiffening structure comprising bodies and bases made of thermosetting composite material, with bodies having longitudinal edges and lateral faces, and bases with plates and tongues, is integrated onto the component surface, allowing for easy adaptation to complex shapes through draping and polymerization processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional manual bonding with multiple components is used, then the component achieves sufficient stiffness, but the manufacturing complexity and time increase significantly
Solution Approach 1:
The patent merges multiple separate bonding operations and components into a single integrated bonding step. The mounting base with pre-formed housing and tongues allows simultaneous bonding of multiple bodies to the component face in one operation, eliminating the need for sequential manual bonding of individual tubes and angle irons.
Solution Approach 2:
The mounting base is prepared in advance with a pre-formed housing and tongues that are already positioned and shaped to receive the bodies. This preliminary preparation of the mounting base with its structural features eliminates the need for on-site assembly and adjustment during the bonding process.
2Strength
If multiple separate components are used for stiffening, then the component achieves sufficient stiffness, but the number of assembly operations increases
Solution Approach 1:
Multiple bodies are combined into a single mounting base structure with a common housing. This allows simultaneous bonding of multiple stiffening elements to the component face in one operation, dramatically reducing the number of assembly steps from multiple individual bondings to a single integrated bonding operation.
3Shape
If custom angle irons are used for each curve, then the component achieves proper fit, but the number of different components required increases
Solution Approach 1:
The mounting base with its pre-formed housing and tongues serves multiple functions: it provides the bonding interface to the component face, houses multiple bodies, and the tongues automatically adapt to the curved surface. This universal structure replaces the need for multiple custom-shaped angle irons with different curves.
Solution Approach 2:
The tongues of the mounting base can be manufactured with different geometries to match various curve radii. By changing the geometric parameters of the tongues during manufacturing, the same basic mounting base structure can adapt to different curved surfaces without requiring fundamentally different component designs.
4Ease of manufacture
If manual bonding at ambient temperature is used, then the bonding process is simple, but the bonding reliability and mechanical strength decrease
Solution Approach 1:
The bonding process transitions from ambient temperature to elevated temperature curing. This parameter change in temperature activates the thermosetting resin, enabling proper curing and achieving high bonding reliability and mechanical strength while maintaining relatively simple process conditions through the integrated mounting base 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
This method simplifies the stiffening process, reduces the number of elements and operations, and ensures high mechanical strength and reliable adhesive bonds, thereby lowering manufacturing costs and improving efficiency.
Implementation Method 1
The stiffening structure is integrated onto the component in a polymerisation step
Data Source
AI summary
Structure intended to stiffen a component made of thermosetting composite material by being fitted to at least one of its surfaces, including: at least one longitudinal body, with first and second longitudinal edge faces on opposite sides, and first and second lateral faces on opposite sides; at least one base including at least one mounting base, each base having a plate and first and second tongues which delimit, with the plate, a housing for at least one body, the first and second tongues extending from a main face of the plate and being pressed respectively against the first and second lateral faces of the body. Each mounting base has a plate which is secured to the first longitudinal edge face of a body and which is intended to be pressed against the surface of the component to be stiffened. Each body and each base are made of thermosetting composite material.