Continuous Consolidation of Stratified Material Using Heated Rollers
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Solution Overview
Problem
Existing methods for continuous consolidation of aircraft coverings using stratified materials with resin and long fibers face issues of non-homogeneous products, surface defects, high operating costs, and potential deformation due to inadequate pressure and temperature distribution, as well as oil leaks and guiding difficulties.
Innovation Solution
A process involving unwinding a fold between two strips along a curved path, with the strips being wider than the fold to ensure contact on both sides, providing uniform heat and pressure, and using guiding means like rollers to maintain tension and prevent deformation, while ensuring homogeneous temperature and pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If step-by-step pressing with two heating plates is used, then consolidation is achieved, but the product is not homogeneous and has surface defects
Solution Approach 1:
The patent implements continuous consolidation by moving the stratified material continuously through the pressing zone between two heated rollers, eliminating the step-by-step operation. This continuous motion ensures uniform pressure and temperature distribution throughout the entire length of the material, producing homogeneous consolidation without surface defects or junction irregularities.
Solution Approach 2:
The patent uses curved roller surfaces instead of flat heating plates. The cylindrical shape of the rollers ensures uniform contact and pressure distribution across the stratified material during continuous pressing, eliminating the junction defects that occur with linear step-by-step pressing operations.
2Manufacturing precision
If folds are heated then laid against rollers in offset manner, then consolidation is achieved, but surface condition is deplorable due to shearing phenomena
Solution Approach 1:
The patent merges the heating and pressing functions into a single simultaneous operation by positioning heated rollers that directly contact and press the stratified material during its continuous passage. This eliminates the time offset between heating and pressing stages, preventing resin shearing and ensuring excellent surface condition.
Solution Approach 2:
The continuous motion of the material through the heated rollers ensures that heating and pressing occur simultaneously and uniformly throughout the consolidation process, eliminating the offset timing that causes surface defects in batch operations.
3Productivity
If material is continuously drawn at the end of consolidation, then movement through stations is ensured, but risk of reinforcement deformation is high
Solution Approach 1:
The curved path created by the rollers and guiding means gently guides the material through the consolidation zone without sharp bends or abrupt movements. This curved geometry prevents deformation of the fiber reinforcement while maintaining continuous motion, unlike linear pulling methods that can distort the stratified structure.
4Manufacturing precision
If oil-filled compartments are used between belts and heating plates, then pressure and heat transfer is improved, but oil leaks can stain material and cause bonding problems
Solution Approach 1:
The patent removes the oil-filled compartments entirely from the system, replacing them with direct contact heated rollers. This eliminates the source of oil leaks and staining while maintaining effective heat and pressure transfer through the roller surfaces that directly contact the stratified material.
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 a high-quality, homogeneous consolidation with reduced operating costs, minimized deformation risks, and improved surface finish, achieving better product quality compared to existing techniques.
Implementation Method 1
A heating plate 14 is provided at each loop so as to apply pressure to the belts to lay the folds 10 against one another
Implementation Method 2
exert tension on said strip so that the latter compresses said at least one fold at least at said curved path
Data Source
AI summary
A process for continuous consolidation of at least one fold (22, 24), whereby the process includes unwinding a unit that consists of the at least one fold (22, 24) that is placed between two strips (26, 28) continuously along at least one curved path, the at least one fold (22, 24) being placed between guiding elements and a strip (26) to the right of the curved path to heat the at least one fold (22, 24) at least at the curved path and to exert tension on the strip (26) so that the latter compresses the at least one fold (22, 24) at least at the curved path, characterized in that it includes using strips (26, 28) whose width is greater than that of the at least one fold (22, 24) so as to be in contact on both sides of the at least one fold (22, 24).