Flexible Vacuum Compaction for Composite Assembly
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Solution Overview
Problem
The construction and assembly of large and complex composite structures, such as airplane fuselage components, are time-consuming and costly due to the serial process of forming support structures and applying composite fibers, necessitating improved material transfer and vacuum compaction devices.
Innovation Solution
The development of flexible material transfer devices and vacuum compaction devices featuring a flexible substrate that can transition between stowed and deployed conformations, with retention and evacuation conduits, and a retention manifold for vacuum application, enabling efficient transfer and compaction of composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If serial processes are used to form support structures and apply composite fibers, then manufacturing precision is maintained, but productivity is reduced and loss of time increases
Solution Approach 1:
The device segments the composite material application process into multiple independent channels, each capable of dispensing composite material simultaneously. This allows parallel construction of composite structure sections, transforming the serial process into a parallel operation that increases productivity while maintaining manufacturing precision through individual channel control
Solution Approach 2:
The device merges multiple composite material dispensing operations into a single integrated tool head that can apply multiple layers and sections simultaneously. By combining support structure formation and skin application in one device, it eliminates the sequential steps required in traditional methods, directly addressing the time loss issue
2Adaptability or versatility
If flexible substrate transitions between conformations are implemented, then adaptability is improved, but device complexity increases
Solution Approach 1:
The device employs a flexible substrate that can transition between different conformations to adapt to various composite structure geometries. This flexible film approach provides the necessary adaptability while keeping the mechanism relatively simple, as the flexibility is inherent in the substrate material rather than requiring complex mechanical joints or actuators
Solution Approach 2:
The substrate is designed to dynamically change its conformation during operation, transitioning from a stowed configuration during transport to a deployed configuration during composite material application. This dynamic adaptability allows the device to handle different structure shapes without requiring multiple specialized tools, balancing versatility with manageable complexity
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
These devices streamline the assembly process by maintaining composite material tension, preventing wrinkling, and reducing assembly time and costs, while accommodating large and complex composite structures.
Implementation Method 1
a plurality of retention conduits that are at least partially defined by the material contacting surface and are configured to have a retention vacuum applied thereto
Implementation Method 2
a plurality of evacuation conduits that are at least partially defined by the material contacting surface
Data Source
AI summary
Flexible material transfer devices, flexible vacuum compaction devices that include the flexible material transfer devices, flexible vacuum chucks that include the flexible vacuum compaction devices, and systems and methods including the same. The flexible material transfer devices include a flexible substrate that is configured to selectively and repeatedly transition between a stowed conformation and a deployed conformation. The flexible substrate defines a material contacting surface that is configured to contact a charge of composite material and to selectively and operatively attach to the charge of composite material. The flexible substrate further defines a plurality of retention conduits that are at least partially defined by the material contacting surface and are configured to have a retention vacuum applied thereto. The flexible material transfer device further includes a retention manifold that provides fluid communication between the plurality of retention conduits and a vacuum source.