Deformable Support for Composite Layup Rotation
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Solution Overview
Problem
The manufacturing of composite articles is time-consuming and costly due to the need for multiple vacuum debulking stages, especially when dealing with complex three-dimensional shapes like aerofoils, where adjacent uncured plies do not adhere strongly, requiring separate vacuum debulking processes for each surface orientation.
Innovation Solution
A method involving a deformable support system where a first grouping of composite material layers is laid on a preform, secured with a deformable support, and then rotated to apply a second grouping on the opposite surface, allowing for a single vacuum debulking stage that includes both groupings and supports, using a clamping arrangement to secure the supports to the preform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple vacuum debulking stages are performed for each surface orientation, then the bond strength between layers is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent combines multiple vacuum debulking operations into a single integrated process by using a deformable support that maintains ply adhesion during preform rotation. This allows vacuum debulking to be performed once after both groupings of plies are applied, eliminating the need for separate debulking stages for each surface orientation.
Solution Approach 2:
The deformable support is applied before rotation to preliminarily secure the first grouping of plies to the preform. This preliminary action prevents ply separation during rotation, enabling the subsequent single vacuum debulking operation to effectively bond both groupings without requiring intermediate debulking steps.
2Productivity
If plies are applied on different surfaces without intermediate vacuum debulking, then manufacturing efficiency is improved, but ply adhesion deteriorates
Solution Approach 1:
The patent changes the physical state of the support from rigid to deformable, allowing it to conform to the preform surface and maintain consistent contact pressure on the plies during rotation. This deformability ensures continuous ply support and adhesion stability without requiring intermediate vacuum debulking operations.
Solution Approach 2:
The deformable support acts as an intermediary between the preform and the plies, providing continuous mechanical support and maintaining ply adhesion during the rotation process. This intermediary element enables efficient single-stage manufacturing while preventing ply separation that would otherwise occur.
3Manufacturing precision
If a rigid support is used to maintain ply orientation during rotation, then ply positioning is improved, but vacuum debulking effectiveness deteriorates
Solution Approach 1:
The patent transitions from a static rigid support to a dynamic deformable support that can adapt its shape during the manufacturing process. The support deforms to conform to the preform surface and maintains optimal contact with plies throughout rotation, ensuring both precise positioning and effective vacuum debulking without compromising either function.
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 reduces manufacturing time and cost by minimizing the number of vacuum debulking stages, improving the bond strength between layers and surface profile conformance, leading to enhanced aerodynamic performance and reduced engine variability.
Implementation Method 1
Vacuum debulking may be used during the manufacture of a composite article to remove gas bubbles that have become trapped between adjacent layers of composite material
Implementation Method 2
disposing a first deformable support over the first grouping of the at least one layer of composite material
Data Source
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AI summary
A method of manufacturing a composite article precursor involving: laying down a first grouping (35a) of at least one layer of composite material upon an upwardly-facing first surface of a substrate; disposing a first deformable support (40) over the first grouping of at least one layer of composite material; securing the first deformable support to the substrate via a first securing fixing (41); rotating the substrate about an axis (37) such the first surface is no longer upwardly-facing and a second surface of the substrate is upwardly-facing; laying down a second grouping (35b) of at least one layer of composite material upon the second surface of the substrate; and vacuum debulking an assembly comprising the first grouping of at least one layer of composite material, the second grouping of at least one layer of composite material, the first deformable support and the substrate.