Thermoplastic Composite Layup Using Electromagnetic First Ply Clamping

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Solution Overview

Problem

Producing thermoplastic composite parts with complex shapes, especially those featuring concave shapes, is challenging due to the difficulty in ensuring the first ply adheres perfectly to the mold without chemical bonding, leading to unsatisfactory industrial solutions.

Innovation Solution

A process involving a hardened first ply with magnetic and/or electrical properties, compatible with thermoplastic resin, is clamped to the tool using a magnetic field or electrical potential difference, allowing perfect adherence and easy demolding, enabling precise shaping of thermoplastic composite layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the first ply is clamped to the mold using mechanical means, then the ply can be maintained on convex molds, but it cannot guarantee perfect adherence to concave mold surfaces

Engineering Contradiction:

Improveadherence of first ply to moldVSAvoidapplicability to concave mold shapes

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent replaces mechanical clamping systems with electromagnetic fields (magnetic or electrical) to hold the first ply on the mold. This substitution enables uniform distribution of holding forces across complex concave surfaces, overcoming the limitation of mechanical clamps that cannot adapt to intricate geometries. The electromagnetic field penetrates and acts uniformly on conductive or magnetic particles distributed throughout the ply, ensuring reliable adherence regardless of mold shape complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If chemical bonding is used to adhere the first ply to the mold, then strong adhesion is achieved, but demolding becomes difficult and resin adherence issues occur

Engineering Contradiction:

Improveadhesion strength of first plyVSAvoiddemolding process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent substitutes chemical bonding mechanisms with physical electromagnetic holding forces. The electromagnetic field provides strong adhesion during the composite laying process without creating chemical bonds that would complicate demolding. When the electromagnetic field is deactivated, the first ply and subsequent composite layers can be easily removed from the mold, eliminating resin adherence issues associated with chemical bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes changes in electromagnetic field parameters (activation/deactivation, field strength modulation) to control the adhesion state. During composite laying, the electromagnetic field is activated to provide strong holding forces. During demolding, the field is deactivated or reduced, causing the holding force to disappear and enabling easy removal without chemical bonding complications.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the first ply is not perfectly adhered to the mold, then demolding is easier, but the composite layers cannot be laid with perfect adherence

Engineering Contradiction:

Improvedemolding easeVSAvoidadherence quality of composite layers

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The electromagnetic holding system provides uniform, controllable forces across the entire mold surface, ensuring perfect adherence of composite layers during laying. The same system enables easy demolding through parameter changes (deactivation), simultaneously achieving both high manufacturing precision and ease of manufacture that cannot be achieved with mechanical clamping or chemical bonding alone.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces dynamic control of the electromagnetic field, allowing the adhesion state to be changed on demand. The field can be activated during composite laying to ensure perfect adherence, then deactivated for easy demolding. This dynamic capability resolves the contradiction between needing strong adhesion during manufacturing and ease of removal afterward.

Inventive Principle:

Principle #15Dynamics

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 ensures perfect adherence of thermoplastic composite layers to the tool, even in concave shapes, without chemical bonding, facilitating the production of complex parts while allowing easy demolding and preventing resin adherence issues.

Implementation Method 1

this first ply being clamped to the tool in the step of laying this first ply on the tool by the effect of a magnetic field established at the level of the tool

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

or of an electrical potential difference between the tool and the first ply

Methodology Applied

Scientific EffectElectrical potential difference: Electric Field

Data Source

PatentUS10773475B2Process for manufacturing a thermoplastic composite part

Publication Date: 2020.09.15 AIRBUS (SAS)

AI summary

This process for producing a thermoplastic composite part by laying of at least one thermoplastic composite layer on a tool includes laying on the tool a hardened first ply before the laying of the thermoplastic composite layer. The first ply is produced beforehand to the shape of the tool and includes a first material able to experience an attractive force when it is subjected to a magnetic field, and/or to an electrical potential difference, and includes a second material of a thermoplastic resin that is chemically compatible with the resin of the thermoplastic composite layer. The first ply is clamped to the tool by the effect of a magnetic field, and/or of an electrical potential difference, established at the level of the tool. In one form of implementation, the first ply is produced on a first-ply mold that is preferably of convex shape.