Continuous Composite Forming Tool with Segmented Pressure Bags
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Solution Overview
Problem
The existing methods for forming aircraft structural components from fiber-reinforced composite materials require large floor-space footprints and are complex, making it difficult to efficiently shape long structural members like flap covers.
Innovation Solution
A forming tool and method using a series of pressurizable pressure bags and a conveying device that allows for continuous forming of semi-finished products with reinforcement fibers, where the pressure bags are inflated or filled with fluid to shape the material, and a controller manages pressure distribution to optimize the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If diaphragm forming with vacuum pressure is used to shape the entire profile length simultaneously, then the prepreg material can be formed into the desired geometry, but the floor-space footprint of the forming plant becomes large
Solution Approach 1:
The forming process is divided into multiple sequential forming zones along the profile length. Instead of forming the entire profile simultaneously, the prepreg material is formed in segments as it progresses through the forming plant, with each zone handling a specific portion of the shaping process
Solution Approach 2:
The forming system transitions from static simultaneous forming to dynamic sequential forming. The prepreg material moves continuously through the forming zones while being shaped progressively, allowing the forming action to follow the material rather than requiring all forming capacity to be present at one location
2Manufacturing precision
If the entire profile length is formed simultaneously using diaphragm forming, then the desired geometry can be achieved, but the forming process becomes complex
Solution Approach 1:
The complex simultaneous forming operation is segmented into multiple simpler sequential forming zones. Each zone performs a simpler shaping task on a smaller portion of the profile, reducing the complexity of individual forming operations while achieving the overall complex geometry through the combination of zones
Solution Approach 2:
The prepreg material undergoes preliminary shaping in early forming zones before reaching later zones. This progressive pre-forming simplifies the work required in subsequent zones, as the material is gradually brought closer to its final geometry rather than requiring all zones to work simultaneously on the complete profile
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 reduces the floor-space footprint, simplifies the forming process, and improves the quality of large formed structures by allowing for efficient shaping of complex geometries with reduced wrinkle formation and improved surface quality.
Implementation Method 1
at least one pressure bag configured to be pressurized during a forming step of the semi-finished product, during which the semi-finished product is sandwiched between a forming surface of a forming element and the at least one pressurized pressure bag
Implementation Method 2
As prepreg forming requires elevated temperatures heat is applied. Therefore, infrared heating devices are commonly installed above the membrane.
Data Source
AI summary
A forming tool for forming a semi-finished product comprising reinforcement fibers and being conveyed to the forming tool in a continuous process. The forming tool comprises at least one pressure bag configured to be pressurized during a forming step of the semi-finished product, during which the semi-finished product is sandwiched between a forming surface of a forming element and the at least one pressurized pressure bag, such that the semi-finished product substantially takes on the shape of the forming surface. Further, a forming apparatus and a forming method for forming a semi-finished product comprising reinforcement fibers are provided.