Composite Tube Wrinkle Control via Compaction Strips
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming composite tubes often result in uncontrolled wrinkle formation, increased costs, longer manufacturing times, and reliability issues due to the inability to incorporate bonded metallic end fittings and require extra cure cycles or tooling.
Innovation Solution
The method involves laying uncured composite material layers over a surface, adding compacted, spaced-apart strips of composite material, and applying pressure to compact and cure them, which allows for controlled wrinkle formation and bonding of metallic end fittings, reducing the need for extra tooling and cure cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional vacuum bagging and autoclave curing methods are used, then composite tubes can be formed, but uncontrolled wrinkle formation occurs
Solution Approach 1:
The method applies preliminary action by placing spacers and compaction strips on the laid-up composite layers before curing begins. These elements pre-position the material to prevent wrinkle formation during the subsequent curing process, rather than attempting to correct wrinkles after they form.
Solution Approach 2:
The patent uses spacers and compaction strips as intermediary elements between the vacuum bag and the composite layers. These intermediaries distribute pressure evenly and maintain proper material spacing during curing, preventing the uncontrolled wrinkle formation that occurs with direct vacuum bagging.
2Manufacturing precision
If metallic wires are inserted into depressions for local compaction, then wrinkle formation control is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent extracts the compaction function from complex metallic wire systems and implements it through simpler spacers and compaction strips that are laid directly on the composite layers. This removes the need for intricate tooling while maintaining wrinkle control capability.
Solution Approach 2:
The spacers and compaction strips used in this method are simple, inexpensive elements that can be easily replaced or adjusted between production runs, unlike expensive metallic wire systems. They perform their compaction function during curing and then serve no further purpose, aligning with the disposable concept.
3Manufacturing precision
If outer diameter tooling is used to apply pressure, then wrinkle formation is controlled, but manufacturing time and cost increase
Solution Approach 1:
The spacers and compaction strips are self-contained elements that perform their own compaction function during the curing process. They automatically distribute pressure and maintain material positioning without requiring external tooling or additional manufacturing steps, thereby reducing production time.
4Adaptability or versatility
If existing methods are used, then composite tubes can be formed, but bonded metallic end fittings cannot be incorporated
Solution Approach 1:
The method allows preliminary positioning and bonding of metallic end fittings to the composite layers before the curing process begins. The spacers and compaction strips are applied after the end fittings are in place, ensuring that the fittings are securely bonded without interfering with the wrinkle control mechanism.
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 results in composite tubes with reduced wrinkle formation, improved mechanical properties, and cost-effective manufacturing by enabling controlled wrinkle formation, bonding of metallic end fittings, and shorter manufacturing times.
Implementation Method 1
compacted, spaced-apart strips of at least one of uncured, partially cured, and completely cured composite material laid lengthwise over the layers of uncured composite material
Data Source
AI summary
In one step of a method of fabricating a composite tube, layers of uncured composite material may be laid over a surface. In another step, spaced-apart strips of at least one of uncured, partially cured, and completely cured composite material may be laid lengthwise over the laid layers of composite material. In still another step, the spaced-apart strips may be compacted against the layers of uncured composite material. In an additional step, the compacted spaced-apart strips and the layers of uncured composite material may be further consolidated and/or cured to form a composite tube.