Corrugated Thermoplastic Composite Stiffening Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The current method of forming composite panels, such as fan cowls, is time-consuming and costly due to the labor-intensive process of laying up thermoset composite plies by hand, which limits efficiency and increases production costs and tooling requirements.
Innovation Solution
A method involving the laying up of thermoplastic resin and fiber plies to form inner and outer skin preforms with alternating peaks and valleys, which are then assembled and bonded at a fusing temperature to create a monolithic stiffening structure, reducing production time and costs by eliminating additional manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset composite plies are laid up by hand one at a time to form a laminate structure, then the structural integrity and stiffness requirements are met, but the production time is excessive and manufacturing cost increases
Solution Approach 1:
The panel is segmented into two separate preforms (inner skin preform with stiffening structure and outer skin preform) that are manufactured independently and then joined together. This allows parallel manufacturing of both preforms rather than sequential layer-by-layer construction, significantly reducing production time while maintaining structural integrity through the corrugated stiffening design.
2Strength
If traditional skin and stringer architecture is used with manual layup, then the required stiffness and strength are achieved, but the manufacturing complexity and tooling requirements increase
Solution Approach 1:
The stiffening structure (traditionally separate stringers) is merged with the skin to form an integrated corrugated structure. The inner skin preform is formed with alternating peaks and valleys that create built-in stiffening, eliminating the need for separate stringer components and reducing manufacturing complexity while maintaining required stiffness.
Solution Approach 2:
The stiffening structure is pre-formed as part of the inner skin preform manufacturing process rather than being added as a separate subsequent step. The corrugated geometry is created during the initial preform formation, performing the stiffening function in advance and simplifying the overall manufacturing process.
3Strength
If separate manufacturing processes are used for skins and stiffeners, then the structural requirements are met, but the number of manufacturing steps and production cost increase
Solution Approach 1:
The manufacturing processes for skins and stiffeners are merged into a single integrated process. Both the inner skin preform (with integrated stiffening structure) and outer skin preform are manufactured using the same thermoplastic preform formation and joining methodology, eliminating the need for different manufacturing processes and improving productivity.
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 method significantly reduces production time and costs, simplifies the manufacturing process, and results in a lighter, more efficient monolithic thermoplastic panel with improved structural integrity, suitable for complex shapes like fan cowls.
Implementation Method 1
heating the inner skin preform and the outer skin preform to a fusing temperature
Implementation Method 2
cooling the inner skin preform and the outer skin preform after consolidating the inner skin preform and the outer skin preform together via the joining
Implementation Method 3
heating the inner skin preform and the outer skin preform to a fusing temperature
Data Source
AI summary
A method may comprise: laying up a first plurality of plies of material comprising thermoplastic resin and fiber to form an inner skin preform, the inner skin preform being a continuous sheet including alternating peaks and valleys; laying up a second plurality of plies of material comprising thermoplastic resin and fiber to form an outer skin preform; and joining the inner skin preform to the outer skin preform.