Composite Tubular Flange Partial Polymerization
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Solution Overview
Problem
Current manufacturing methods for aerospace and aeronautical composite tubular parts are not industrially viable due to high costs and weight associated with metal flanges, which hinder their widespread adoption.
Innovation Solution
A method involving the use of thermosetting materials with partial polymerization for forming composite tubular parts, where flange components are partially polymerized to reduce deformation and facilitate assembly, allowing for the creation of large-sized flanges with improved bonding and reduced mass and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal flanges are used for assembly, then structural strength and connection reliability are improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent changes the material parameter from metal to composite material for the flange, transforming it from a rigid high-strength material to a lightweight composite structure that maintains sufficient connection reliability while dramatically reducing weight
Solution Approach 2:
The patent employs composite materials (carbon fiber reinforced plastic) to manufacture the flange, replacing traditional metal flanges. This allows the flange to achieve an optimal balance between strength, weight, and manufacturing feasibility through the inherent properties of composite materials
2Strength
If metal flanges are used for assembly, then connection strength is improved, but manufacturing cost and assembly cost increase
Solution Approach 1:
The patent merges the flange manufacturing process with the tubular body manufacturing process by integrating the flange as an extension of the tubular body in the composite molding process. This eliminates separate metal flange manufacturing and assembly operations, reducing both manufacturing cost and assembly complexity while maintaining connection strength
Solution Approach 2:
The patent replaces the mechanical assembly system (separate metal flange attachment) with an integrated composite molding system, where the flange is formed as part of the tubular body in a single composite structure, eliminating the need for separate manufacturing and assembly steps
3Weight of moving object
If composite materials are used for tubular parts, then weight is reduced, but manufacturing complexity and polymerization control difficulty increase
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: tubular body formation, flange component formation with partial polymerization, assembly, and final polymerization. This segmentation allows complex polymerization to be controlled in manageable steps, reducing manufacturing process complexity while maintaining weight advantages of composite materials
Solution Approach 2:
The patent performs preliminary partial polymerization of the flange component before assembly with the tubular body. This preliminary action stabilizes the flange component for handling and assembly while avoiding the complexity of fully polymerizing large structures in one step, simplifying the overall manufacturing process
4Adaptability or versatility
If large-sized flanges are manufactured, then connection versatility is improved, but deformation during manufacturing and assembly increases
Solution Approach 1:
The patent applies preliminary partial polymerization to the flange component before assembly, which provides sufficient structural stability to prevent deformation during handling and assembly of large-sized flanges, while allowing the final polymerization to occur after proper positioning is achieved
Solution Approach 2:
The patent changes the polymerization parameter from complete to partial during the intermediate stage, creating a state where the flange has enough rigidity to maintain dimensional stability for large structures, yet remains workable for assembly 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
Enables the production of lightweight, cost-effective composite tubular parts with enhanced assembly solidity and ease of connection, addressing the limitations of traditional metal flange-based solutions.
Implementation Method 1
performing a first heat treatment to partially polymerize the flange component or components
Implementation Method 2
performing a first heat treatment to partially polymerize the flange component or components
Implementation Method 3
performing a second heat treatment of the composite assembly so as to polymerize both the at least one tubular body portion and the flange component or components
Data Source
AI summary
A method for manufacturing an aerospace and/or aeronautical composite tubular part, the composite tubular part includes a tubular body and at least one flange. The method includes the following steps: providing at least one composite tubular body portion; forming at least one flange component from a second thermosetting material; a first heat treatment to partially polymerize the flange component or components; assembling the flange component or components on the composite tubular body; a second heat treatment of the composite assembly so as to polymerize both the at least one tubular body portion and the flange component or components. A composite tubular part is also provided.