Fibre Composite Component Manufacturing with Local Thickness Build-Up
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing large-format fiber-reinforced plastic components, such as aircraft fuselage shells, are complex, time-consuming, and require high-capacity automated fiber deposition devices, limiting production speed and flexibility, especially when varying thicknesses are needed.
Innovation Solution
A method involving the use of a first planar fabric with consistent thickness as a base, combined with additional second fabrics to increase thickness where needed, and stiffening elements, using processes like AFP and ultrasound bonding, followed by consolidation under pressure to create a composite structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated fiber deposition devices are used to produce large-format components with variable thickness, then manufacturing precision and adaptability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The component is divided into a base layer produced by efficient processes and additional fabrics added in specific regions. This segmentation allows different manufacturing approaches for different parts, avoiding the need for complex automated deposition across the entire large-format component while achieving variable thickness where needed.
Solution Approach 2:
Additional fabrics are applied only in specific regions where thickness variation is required, rather than using complex automated deposition throughout the entire component. This local approach achieves the needed thickness control without requiring high-capacity automated fiber deposition devices for the whole structure.
2Productivity
If conventional molding processes are used for large-format components, then manufacturing simplicity is maintained, but production speed is limited
Solution Approach 1:
The base layer is produced in advance using efficient manufacturing processes such as double-belt press or automated fiber positioning, which can operate continuously at high speed. This preliminary production of the main component area enables faster overall manufacturing compared to conventional step-by-step molding.
Solution Approach 2:
Multiple manufacturing steps are combined into a single consolidation process where the base layer and additional fabrics are bonded together in one operation using ultrasound, laser irradiation, or localized heating. This merging of operations reduces total manufacturing time while achieving variable thickness.
3Productivity
If high-capacity automated fiber deposition devices are used, then production speed can be increased, but device complexity and cost increase
Solution Approach 1:
The production process is segmented into base layer manufacturing using simple, efficient processes and subsequent addition of reinforcement fabrics. This avoids the need for high-capacity automated fiber deposition devices that would be required to produce the entire component in one continuous process.
Solution Approach 2:
The bonding of additional fabrics to the base layer is achieved through ultrasound, laser irradiation, or localized heating instead of mechanical fiber deposition. This substitution of bonding methods allows for rapid assembly without requiring complex automated fiber placement equipment.
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 rapid and efficient production of large-format components with variable thicknesses and enhanced strength, reducing the need for large, costly deposition devices and allowing for larger components like fuselage shells over 20 meters in length.
Implementation Method 1
The composite of the at least one first planar fabric, the second fabrics and the stiffening elements is consolidated, at least by applying pressure
Implementation Method 2
The individual resin-coated fiber ribbons could be bonded together using ultrasound
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method for manufacturing a component (42) is proposed, in which at least one first planar fabric (24, 26) is produced from a fiber-reinforced composite material with a constant thickness, an outer surface (32, 36), and an inner surface (34, 38). At least one second planar fabric (28, 40) is arranged on the first planar fabric (24, 26) and subsequently consolidated. The first planar fabric (24, 26) can be provided in a continuous, efficient manufacturing process, which increases speed and reduces costs.