Deformable Transition Elements for Composite Laminate Forming
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Solution Overview
Problem
Existing systems for forming composite materials are limited in creating complex geometries and variable section laminates, often resulting in wrinkles and increased costs due to the need for multiple rollers and complex pressure adjustment systems.
Innovation Solution
A system utilizing deformable transition elements and a flexible counter-form that can adapt to different geometries, providing heat and traction to prevent wrinkles, allowing for the formation of laminates with variable sections and thicknesses, and enabling automatic threading and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple rollers with pressure adjustment systems are used to form simple geometric shapes, then the forming capability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent employs flexible membranes as forming elements that can be inflated or deflated to adapt to different geometric shapes. This single flexible membrane system replaces multiple rigid rollers with pressure adjustment systems, reducing device complexity while maintaining versatility in forming different geometries including omega-shaped cross-sections, twisted geometries, and complex profiles.
Solution Approach 2:
The flexible membrane system serves multiple functions: it acts as both the forming surface and the pressure application mechanism. By inflating or deflating the membrane, the same component can adapt to various geometries, eliminating the need for multiple specialized rollers and their respective control systems.
2Adaptability or versatility
If multiple rollers are used to form composite materials, then the forming capability is improved, but the manufacturing precision deteriorates due to wrinkle formation
Solution Approach 1:
The flexible membrane provides a smooth, conforming surface that gradually shapes the composite material without creating sharp pressure points or folds. The membrane's flexibility allows it to adapt to the material's deformation, preventing wrinkle formation while maintaining the ability to form complex geometries with high precision.
Solution Approach 2:
The membrane system is dynamic, allowing controlled inflation and deflation during the forming process. This dynamic adjustment enables the membrane to maintain optimal contact with the composite material throughout deformation, ensuring smooth forming without wrinkles while achieving precise geometric outcomes.
3Adaptability or versatility
If rollers are used to form variable section laminates, then the forming capability is improved, but the device complexity increases due to the need to change rollers
Solution Approach 1:
The flexible membrane system is inherently dynamic, allowing continuous adjustment of its shape and volume through inflation/deflation control. This enables the formation of variable section laminates without physically changing components, as the membrane can be programmed to assume different configurations corresponding to different target geometries.
Solution Approach 2:
The system controls the forming process by changing parameters (inflation pressure, membrane tension) rather than changing physical components. By adjusting these parameters, the same membrane can form laminates with varying sections along their length, eliminating the complexity of having multiple specialized rollers for different section types.
4Adaptability or versatility
If a pneumatic cover with pressurized fluid is used to form laminates, then the adaptability to different geometries is improved, but the energy consumption increases
Solution Approach 1:
The membrane system uses periodic or pulsed inflation rather than continuous pressurization. The membrane is inflated only during the actual forming operation and deflated when changing geometries or between operations, significantly reducing overall energy consumption while maintaining the ability to adapt to different geometries when needed.
Solution Approach 2:
The system recovers energy by deflating the membrane after forming operations. The pressurized fluid is released or reused for the next forming operation, rather than continuously consuming energy to maintain pressure. This cyclical use and recovery approach reduces net energy consumption while preserving geometric adaptability.
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
Enables the formation of complex geometries and variable section laminates without wrinkles, reducing system complexity and cost, while maintaining quality and efficiency.
Implementation Method 1
said transition elements provide heat
Implementation Method 2
deformable transition elements that adopt a variable section... providing heat and traction to prevent wrinkles
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The system for forming stacks of composite materials comprises a form (1) which defines the section that is desired to provide to a stack (2) of composite material placed thereon to obtain a formed stack (2'); a counter-form (3), which together with the form (1), forms and obtains the formed stack (2'); and it is characterized in that the system also comprises transition elements (4) deformable, that adopt a variable section from an initial section in one of its ends and the end section defined by the form (1) in the other end. It allows changing the geometry during the forming of the laminate, to obtain laminates of variable section along its length. For this purpose, the form and counter-form must have a variable geometry at will.