Integrated Composite Stringer Forming and Curing Tool
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Solution Overview
Problem
Current manufacturing processes for composite structures, such as blade stringers, require multiple tools for forming and curing, leading to increased manufacturing time, potential material inconsistencies, higher upfront costs, and risk of tolerance stack-up due to tool transfer, and inefficient energy consumption from separate forming and curing processes.
Innovation Solution
A forming and curing tool that integrates both functions using a single tool set, comprising dies with vacuum paths, flexible bladders, and a wedge mechanism to simultaneously form and cure composite stringers by applying heat and pressure, reducing the need for multiple tools and streamlining the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple tools are used for forming and curing, then the forming and curing functions can be performed, but manufacturing time increases and material inconsistencies occur
Solution Approach 1:
The patent combines forming and curing tools into a single integrated tool set. The forming tool includes a forming cavity, forming platens, and curing platens all within one tool assembly, eliminating the need to transfer parts between separate forming and curing tools. This merging directly reduces manufacturing time and prevents material inconsistencies that occur during tool transfers.
Solution Approach 2:
The forming tool is designed to perform multiple functions: forming the composite structure, curing the resin, and infusing resin through vacuum. The tool includes both forming platens and curing platens that can be activated in sequence or simultaneously, allowing a single tool to complete what previously required multiple specialized tools.
2Ease of manufacture
If multiple tools are used for forming and curing, then the forming and curing functions can be performed, but capital costs increase
Solution Approach 1:
The patent consolidates multiple tooling systems into one integrated forming and curing tool. By combining the forming cavity, forming platens, and curing platens into a single tool set, the capital investment required for tooling is reduced compared to purchasing and maintaining separate forming and curing tools.
Solution Approach 2:
The multi-functional tool design allows a single tooling system to handle both forming and curing operations, reducing the total number of tools required and thereby lowering capital costs associated with tooling infrastructure.
3Ease of manufacture
If multiple tools are used for forming and curing, then the forming and curing functions can be performed, but tolerance stack-up risk increases
Solution Approach 1:
The patent eliminates tool transfer by integrating forming and curing in a single tool. The forming cavity and curing platens are designed with precise dimensional relationships that ensure consistency. By completing both operations in one tooling system, the cumulative tolerances that would result from transferring parts between tools are avoided, thereby reducing tolerance stack-up risk.
4Ease of manufacture
If separate forming and curing processes are used, then the forming and curing functions can be performed, but energy consumption increases
Solution Approach 1:
The integrated tool allows the forming and curing processes to continue without interruption. The forming platens can be activated, followed immediately by curing platens, eliminating idle time between processes. This continuous operation reduces the total energy consumption compared to separate forming and curing cycles that would require heating and cooling periods between 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 integrated approach reduces manufacturing time, minimizes material inconsistencies, lowers capital costs, and optimizes energy use by allowing for simultaneous forming and curing within a single tool, enhancing the efficiency and quality of composite stringer production.
Implementation Method 1
a number of flexible bladders surrounding the stiffener
Implementation Method 2
a number of vacuum paths through the first die
Implementation Method 3
the part is exposed to elevated temperature and pressure for cure
Implementation Method 4
a wedge connected to the stiffener
Data Source
AI summary
Forming and curing tools and method of forming a blade stringer. A first cut and kitted material and a second cut and kitted material are clamped between a first die and a second die. The first cut and kitted material and the second cut and kitted material are formed against the first die and the second die while the first cut and kitted material and the second cut and kitted material are clamped. A noodle and base material are applied over the first cut and kitted material and second cut and kitted material. A composite stringer preform comprising the first cut and kitted material, the second cut and kitted material, the noodle, and the base material is cured while the composite stringer preform is against the first die and the second die.