Corrugated Wrinkle Diffuser for Composite Laminate
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Solution Overview
Problem
In composite materials manufacturing, excess ply material often forms uncontrolled wrinkles when draped over tools with irregular geometric shapes or complex curvature, leading to significant documentation and rework, or even scrapping of composite articles, resulting in cost and schedule impacts.
Innovation Solution
A wrinkle mitigation system using tooling rods or wrinkle diffusers with corrugated surfaces is applied to the tool surface, where the composite ply overlaps, causing the ply to assume a corrugated shape under compaction pressure, thereby controlling and diffusing wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If composite plies are draped over a tool surface with irregular geometric shape or complex curvature, then the composite structure can be formed to match the desired geometry, but excess ply material builds up and causes uncontrolled wrinkle formation
Solution Approach 1:
A tooling rod is introduced as an intermediary element between the composite ply and the tool surface. The rod has a rounded leading end that contacts the ply first, guiding it over the complex curvature region. This intermediary prevents direct contact between the ply and the problematic tool surface geometry, thereby controlling wrinkle formation while still achieving the desired complex shape
Solution Approach 2:
The tooling rod is positioned on the tool surface before the composite ply is applied. By pre-placing the rod at the specific location where complex curvature causes wrinkle buildup, the system prepares the path for the ply in advance, ensuring that the ply is guided correctly as it is draped over the tool surface
2Manufacturing precision
If excess ply material is allowed to build up at localized areas, then the composite can conform to the tool surface geometry, but uncontrolled wrinkles form requiring significant rework or scrapping
Solution Approach 1:
The tooling rod acts as a mediator that allows the composite ply to conform to the tool surface geometry without direct contact between the ply and the problematic areas. The rod's rounded leading end gradually guides the ply over the curvature, preventing sudden buildup and wrinkle formation, thereby maintaining geometric conformity while eliminating the need for rework or scrapping
3Manufacturing precision
If the tooling rod has a high aspect ratio with small rod width, then the composite ply assumes a controlled corrugated shape, but the rod may be more difficult to position and remove
Solution Approach 1:
The aspect ratio of the tooling rod is optimized to balance two competing requirements: a higher aspect ratio with smaller width provides better control over the corrugated shape of the composite ply, while a lower aspect ratio with larger width makes the rod easier to position and remove. The specific parameters are selected to achieve the minimum width needed for adequate control while maintaining ease of operation
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
The system effectively minimizes wrinkle formation by uniformly distributing excess ply material, reducing the need for rework and costly replacements, and improving the quality and efficiency of composite article production.
Implementation Method 1
The tooling rod may have a rod width that results in the composite ply assuming a corrugated shape when compaction pressure is applied to the composite ply over the tooling rod
Data Source
AI summary
A system for diffusing wrinkles in a composite laminate may include at least one wrinkle diffuser. The wrinkle diffuser may include a diffuser body may be mounted to a tool in a manner such that a composite ply at least partially overlaps the wrinkle diffuser. A plurality of diffuser elements may be formed in the diffuser body to define a corrugated surface. The corrugated surface may cause a portion of the composite ply to assume a corrugated shape when a compaction pressure is applied to force the composite ply against the corrugated surface. The wrinkle diffuser may include an indexing feature to index the wrinkle diffuser to a ply edge of the composite ply.