Flexible Caul Plate for Uniform Composite Compaction

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Solution Overview

Problem

Existing methods for assembling elongate composite structures, such as those using rigid cure tools, are ineffective in uniformly compacting composite materials with varying thickness or number of plies, leading to inconsistent compaction and assembly quality, especially as the size and length of the composite materials increase.

Innovation Solution

The use of a flexible elongate caul plate and vacuum compaction film in conjunction with rigid elongate cure tools, allowing for relative translation and vacuum application to uniformly compact and join elongate charges of composite material, ensuring consistent compaction across varying thicknesses and lengths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If rigid elongate cure tools are used to support and compact composite material charges, then structural stability and support are improved, but compaction uniformity deteriorates in regions with varying thickness or number of plies

Engineering Contradiction:

Improvestructural stabilityVSAvoidcompaction uniformity

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

A flexible membrane is introduced between the rigid cure tool and the composite material charge. This flexible membrane conforms to the varying thickness and ply configuration of the charge, distributing compaction force uniformly across the entire surface. The rigid cure tool provides structural stability while the flexible membrane ensures compaction uniformity by adapting to local geometry variations.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible membrane acts as an intermediary element between the rigid cure tool and the composite material charge. It mediates the transmission of compaction force, transforming the rigid tool's uniform pressure into locally adapted pressure distribution that matches the charge's varying thickness profile, thereby achieving both structural support and compaction uniformity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Length of moving object

If the size and length of composite material charges and cure tools increase, then the capacity to assemble larger structures is improved, but compaction uniformity deteriorates

Engineering Contradiction:

Improvestructure sizeVSAvoidcompaction uniformity

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The flexible membrane's ability to conform to varying geometries becomes increasingly important as structure size increases. For larger charges with greater thickness variations, the flexible membrane maintains uniform compaction by adapting to each local region, preventing the compaction non-uniformity that would otherwise occur in large-scale assemblies.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible membrane introduces dynamic adaptability to the otherwise static rigid cure tool system. As the membrane deforms under vacuum pressure, it dynamically adjusts its shape to match the charge's geometry, ensuring uniform compaction across the entire large-scale structure regardless of thickness variations.

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 approach enables a more uniform and robust joining of composite materials, improving the assembly quality by conforming to the shape of the composite material and maintaining consistent compaction force, even in regions with varying thickness or number of plies, resulting in a stronger and more consistent elongate composite structure.

Implementation Method 1

a vacuum source configured to apply a vacuum to the enclosed volume

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

heating the elongate composite assembly to cure the FEC and the SEC

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS11820081B2Systems and methods for assembling elongate composite structures

Publication Date: 2023.11.21 THE BOEING CO

AI summary

Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.