Flexible Compactor Reinforcing Spine for Composite Layup

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Solution Overview

Problem

Existing flexible compactors for contoured composite stiffeners are prone to deformation and kinking, leading to inconsistent ply wrinkling and fiber distortion during the layup process, which affects part quality and performance, and lack durability for repeated use.

Innovation Solution

A flexible compactor with a reinforcing spine that extends through a flexible joint, allowing the compactor to conform to complex geometries while maintaining structural integrity, preventing deformation and ensuring consistent load transfer, comprising a cap portion with flexible joints and laminated plies of fiber-reinforced resin, and transverse reinforcement strips.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If flexible material (rubber) is used in compactor areas, then the compactor can conform to complex geometries, but repeated use causes deformation and buckling

Engineering Contradiction:

Improveconformability to complex geometriesVSAvoiddurability against deformation and buckling

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The compactor uses a composite structure combining flexible rubber material with rigid reinforcement elements (spines and strips). The rubber provides conformability to complex geometries while the reinforcement elements prevent deformation and buckling during repeated use, resolving the contradiction between adaptability and reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The reinforcement elements are strategically positioned at specific locations within the rubber material where structural support is most needed. This localized reinforcement maintains flexibility in non-critical areas while preventing deformation in critical load-bearing areas, achieving both conformability and durability.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If hand layup techniques are used, then the process can accommodate complex contours, but ply wrinkles and fiber distortion occur

Engineering Contradiction:

Improveability to handle complex contoursVSAvoidcontrol of ply wrinkles and fiber distortion

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The flexible compactor acts as an intermediary tool between the operator and the composite layup. It provides consistent, controlled pressure distribution across complex contours, eliminating the variability and imprecision of direct hand manipulation while maintaining the ability to conform to intricate geometries.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The compactor transforms the manual, variable pressure application of hand layup into a controlled, consistent pressure distribution. By changing the method of force application from direct human manipulation to mediated mechanical pressure, the process achieves better control over ply placement and reduces defects.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If flexible material is used without reinforcement, then the compactor can flex in multiple planes, but permanent deformation occurs after repeated use

Engineering Contradiction:

Improveflexibility in multiple planesVSAvoidservice life under repeated use

Core Design Contradiction:

Ease of operationVSDuration of action of stationary object

Solution Approach 1:

The compactor combines flexible rubber material with rigid reinforcement elements to create a composite structure. The rubber enables multi-plane flexibility for ease of operation, while the reinforcement elements prevent permanent deformation and extend service life under repeated use.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The reinforcement elements are built into the compactor structure beforehand to prevent deformation before it occurs. This proactive reinforcement ensures the compactor maintains its structural integrity and flexibility throughout its service life, even under repeated stress.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

The flexible compactor consistently regulates ply wrinkling and gathering, improving part quality and performance, and maintains its geometry and load transfer properties even after repeated use, making it suitable for high-rate production environments.

Implementation Method 1

The flexible joint includes a rubber that is longitudinally reinforced by the spine. The flexible joint is located within the cap portion and allows the cap portion to flex along at least a first plane.

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The compactor employs a reinforcing spine that prevents permanent deformation and/or undesired of buckling or kinking of the compactor.

Methodology Applied

Scientific EffectStructural reinforcement:

Data Source

PatentUS10195811B2Flexible compactor with reinforcing spine

Publication Date: 2019.02.05 THE BOEING CO

AI summary

A device for compacting a contoured elongate composite layup includes flexible first and second fiber reinforced resin flexible sections flexible along their lengths. The first section is flexible within a first plane and the second section is flexible within the first plane as well as within a second plane. The second section includes flexible joints reinforced by a spine.