Flexible Textured Blanket for Single-Step Composite Panel Embossing
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Solution Overview
Problem
Existing methods for forming decorative, textured surfaces on curved or contoured panels in the aircraft industry are inefficient, as they require separate labor-intensive processes and can damage the decorative film due to high forces, and fail to effectively mask underlying surface features.
Innovation Solution
A method and apparatus that use a flexible, textured blanket within a compression mold to emboss a textured surface onto a panel in a single process, eliminating the need for multi-opening presses and vacuum forming, and allowing for the use of aluminum crushed-core mold dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a textured mold tool face is used to emboss a decorative pattern on the decorative film during panel formation, then the panel acquires a textured surface, but the textured pattern locks the film within the mold resulting in damage to the decorative film during removal
Solution Approach 1:
The patent uses a flexible blanket with a textured outer surface instead of a rigid textured mold tool face. The blanket's flexibility allows it to conform to the mold cavity while transferring the texture to the decorative film, and then be easily removed without locking the film in place, thus preventing film damage during panel removal
Solution Approach 2:
The flexible blanket acts as an intermediary between the rigid mold cavity and the decorative film. It transfers the textured pattern to the film during formation but can be separately removed afterward, avoiding the direct locking effect that occurs with rigid textured mold surfaces
2Strength
If high force is used to form the panel in the compression mold, then the panel achieves proper consolidation, but the thin decorative film is damaged due to the same high force
Solution Approach 1:
The flexible blanket provides a compliant surface that distributes the consolidation force more evenly across the decorative film, preventing localized stress concentrations that would damage the thin film while still achieving adequate panel consolidation
Solution Approach 2:
The patent changes the physical parameter of the tooling surface from rigid to flexible, which alters how force is transmitted to the decorative film during panel formation, reducing peak stresses while maintaining consolidation pressure
3Shape
If a separate multi-opening press process is used to texture the decorative film, then the film acquires a textured surface, but the process becomes labor and capital intensive
Solution Approach 1:
The patent merges the panel formation process with the surface texturing process by incorporating the textured flexible blanket directly into the compression mold. This eliminates the separate multi-opening press operation, reducing both equipment requirements and manufacturing complexity
Solution Approach 2:
The compression mold is given multi-functionality by using a flexible blanket that serves both as a forming tool and a texturing tool in a single operation, eliminating the need for dedicated texturing equipment
4Shape
If the decorative film is placed in the mold before panel formation, then the texture can be embossed, but the underlying rough surface features become visible through the thin film
Solution Approach 1:
The flexible blanket provides a compliant backing that fills in and masks the underlying rough surface features of the pre-preg skin and core pattern, while still allowing the textured pattern to be clearly imprinted on the decorative film surface
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 the efficient fabrication of panels with textured surfaces in a single mold, reducing costs and preventing damage to the decorative film, while effectively masking underlying features, and can be used for various applications in the transportation industry.
Implementation Method 1
A pressure chamber placed over the mold is used to press the shell against the textured blanket, thereby imparting the texture on the blanket to the surface of the shell
Implementation Method 2
a flexible tool having a textured surface on one side thereof, the flexible tool being removably installed in and conforming to the shape of at least a portion of the contoured mold cavity
Implementation Method 3
a pressurizer positionable over the mold cavity for pressing the material charge against the combination of the flexible tool and the mold cavity
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
Decorative textured surfaces (54) are formed on articles having curved or contoured surfaces. A reusable, flexible textured blanket (46) is placed in a mold (34) along with a first material charge. A pressurizer (44) is used to both impart the texture of the blanket to the first material charge and consolidate the charge to form a textured shell. A second material charge is introduced into the mold over the shell. The application of heat and pressure consolidates the second material charge and the shell to both form and cure the completed article