Flexible Intermediate Member for Laminate Panel Assembly
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Solution Overview
Problem
The existing methods for forming laminate panels using an intermediate member with a complex curved shape face difficulties in assembly due to wrinkle formation and require manual or time-consuming assembly processes, and the panels tend to spring back to their original shape when the vacuum is released.
Innovation Solution
A method and apparatus that utilize a flexible intermediate member supported by a lay-up table, with a vacuum bag creating a partial vacuum to shape the panel, and an airtight seal to maintain the shape, allowing for automated assembly and preventing panel springback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If an intermediate member with a complex curved shape is used to form a shaped panel, then the panel can achieve the desired complex shape, but the assembly process becomes difficult and time-consuming due to wrinkle formation
Solution Approach 1:
The patent divides the assembly process into two distinct stages: first assembling the lay-up on a flat intermediate member, then transferring to a shaped surface. This segmentation allows the assembly process to be performed under controlled flat conditions, avoiding wrinkle formation, while still achieving the desired complex shape in the final product.
Solution Approach 2:
The patent performs the assembly of the lay-up on a flat intermediate member before transferring to the shaped surface. This preliminary action of assembling on a flat surface eliminates the wrinkle formation problem that would occur if assembly were performed directly on the complex curved shape, while the final shaped configuration is achieved through the transfer and forcing process.
2Manufacturing precision
If manual assembly is used to avoid wrinkles, then the panel can be assembled without wrinkles, but the process becomes time-consuming and expensive
Solution Approach 1:
The patent introduces a flat intermediate member as a mediator that enables automated assembly. The intermediate member provides a flat working surface that allows automated lay-up processes, while still achieving the desired complex shape through the subsequent transfer and forcing against the shaped surface. This intermediary resolves the contradiction by enabling both automated assembly and wrinkle-free production.
3Ease of operation
If the intermediate member is made flat to simplify assembly, then assembly becomes easier and faster, but the member bows as plies are assembled due to inherent flexibility
Solution Approach 1:
The patent utilizes the dynamic flexibility of the intermediate member in a controlled manner. The intermediate member is made flexible enough to be easily manipulated and positioned, but its flexibility is harnessed during the forcing stage against the shaped surface to achieve the desired configuration. The flexibility is not a defect but a feature that is actively utilized to achieve both ease of assembly and final shaped configuration.
4Ease of operation
If vacuum is released to remove the vacuum bag, then the vacuum bag can be removed for access, but the panel springs back to its original shape
Solution Approach 1:
The patent performs the shaping and curing process while the vacuum is still applied, and maintains the vacuum throughout the curing cycle. This preliminary action of completing the shaping and curing before vacuum removal ensures that the panel retains its shaped form. The vacuum is only removed after the panel has been shaped and cured, preventing springback while still allowing vacuum bag removal for access during the process.
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 efficient and automated assembly of laminate panels with reduced time and cost, while maintaining the shaped form even after vacuum release through the use of a vacuum chamber and airtight seals.
Implementation Method 1
generating a partial vacuum between the vacuum bag and the shaped surface
Implementation Method 2
forcing the lay-up against the shaped surface, via the intermediate member, in a manner that modifies the shape of the lay-up
Implementation Method 3
forming an airtight seal between the intermediate member and a vacuum box in order to form a vacuum chamber
Data Source
AI summary
A method of assembling and shaping a laminate panel. An intermediate member is mounted on a lay-up table and a lay-up is assembling by laying a series of plies onto the intermediate member on the lay-up table. The intermediate member and the lay-up are then removed from the lay-up table and placed them on a shaped surface. The lay-up is then forced against the shaped surface, via the intermediate member, in a manner that modifies the shape of the lay-up to form a shaped laminate panel. Finally the shaped laminate panel is removed from the intermediate member. The lay-up table can thus support the flexible intermediate member during assembly, and can be relatively flat to enable the lay-up to assembled by an automated process.