Composite Stringer Manufacturing System with Integrated Bladder Wrap

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Solution Overview

Problem

Conventional methods for manufacturing composite stringers are labor-intensive, time-consuming, and require dedicated equipment, leading to increased production costs and space requirements, as well as a complex process for installing wrapped bladder assemblies.

Innovation Solution

A manufacturing system comprising a first and second mandrel, with wrap plates that translate to form a gap to receive a bladder, allowing for the automated or semi-automated layup and wrapping of a wrap laminate around the bladder to form a wrap-bladder assembly, which can be co-bonded with a stringer laminate to create a composite structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional methods are used to install wrapped bladder assemblies on composite stringers, then the bladder assembly can be properly installed, but the process becomes labor-intensive and time-consuming

Engineering Contradiction:

Improveease of installing wrapped bladder assemblyVSAvoidinstallation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent combines the stringer manufacturing process with the wrapped bladder assembly installation process into a single integrated operation. The wrap laminate is applied to the stringer laminate in one continuous process, eliminating the need for separate installation steps and reducing both labor intensity and time requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The wrap laminate is prepared and positioned on the stringer laminate before curing occurs. This preliminary positioning allows the bladder assembly to be integrated into the stringer structure during the layup phase, rather than requiring separate installation operations after the stringer is formed.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If dedicated equipment is used for manufacturing wrapped bladder assemblies, then the assembly can be properly manufactured, but the production cost increases

Engineering Contradiction:

Improvequality of wrapped bladder assemblyVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The manufacturing system is designed to perform multiple functions using the same equipment. The same apparatus that manufactures the composite stringer also manufactures the wrapped bladder assembly by applying wrap laminate to the stringer laminate. This eliminates the need for dedicated separate equipment and reduces production costs while maintaining quality standards.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If separate equipment is used for manufacturing composite stringers and wrapped bladder assemblies, then each component can be manufactured independently, but the production floor space requirement increases

Engineering Contradiction:

Improveindependent manufacturing capabilityVSAvoidproduction floor space

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The patent merges the manufacturing of composite stringers and wrapped bladder assemblies into a single integrated process using the same equipment. The wrap laminate is applied to the stringer laminate in-situ during the stringer manufacturing process, eliminating the need for separate manufacturing stations and reducing production floor space requirements.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of operation

If conventional methods are used to transport and install wrapped bladder assemblies, then the assembly can be installed in the stringer cavity, but the production rate decreases

Engineering Contradiction:

Improveease of installing bladder assemblyVSAvoidproduction rate

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The wrap laminate is positioned and applied to the stringer laminate during the initial layup phase, before the stringer is cured and removed from the mandrel. This preliminary action eliminates the need for subsequent transportation and installation operations, as the bladder assembly is already in place when the stringer is formed, thereby maintaining production rate.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3753699B1System and method for manufacturing a composite assembly

Publication Date: 2024.06.05 THE BOEING CO

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AI summary

A system for manufacturing a composite assembly includes a first mandrel, a second mandrel, a first wrap plate, and a second wrap plate. The first wrap plate and the second wrap plate are positionable in side-by-side relation for receiving a wrap material stack. The first wrap plate and/or the second wrap plate are translatable to a wrap plate open position defining a wrap plate gap between the first and second wrap plate surface edge for receiving a bladder. The second mandrel is translatable to a mandrel open position defining a mandrel gap between the first and second mandrel surface edge. The wrap plate gap and the mandrel gap are configured to receive the wrap material stack formed around a bladder. The first and second wrap plate are configured to fold a first and second material stack base portion into overlapping relation with each other on the bladder top.