Fly-away Bag Carrier for Co-cured Composite Structures
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Solution Overview
Problem
Conventional composite manufacturing techniques for aircraft components are time-consuming, labor-intensive, and weight-increasing due to mechanical fastening, and struggle with assembling complex shapes, especially in hollow structures where internal support structures often remain post-curing, disrupting aerodynamics.
Innovation Solution
A method involving a co-cured composite article with an integrated fly-away bag carrier, where a vacuum bag surrounds the bag carrier, and an outer skin is pressed against it, with a filler in between, allowing for simultaneous curing and forming of complex shapes without the need for post-curing assembly and reducing weight by eliminating unnecessary support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cured composite components are assembled separately using mechanical fasteners, then structural strength is achieved, but manufacturing time and labor intensity increase significantly
Solution Approach 1:
The patent merges the bag carrier with the composite skin members by co-curing them together in a single manufacturing process. The bag carrier is positioned within the mold, composite materials are laid up around it, and both are cured simultaneously to form an integrated structure, eliminating separate assembly operations and mechanical fasteners.
Solution Approach 2:
The bag carrier is prepared and positioned within the mold before the composite materials are laid up. This preliminary positioning allows the composite materials to be formed around the carrier in the correct configuration, enabling co-curing and eliminating the need for post-curing assembly operations.
2Strength
If mechanical fasteners are used to assemble composite components, then structural connection is achieved, but overall weight of the composite structure increases
Solution Approach 1:
The bag carrier and composite skin members are merged into a single co-cured structure, eliminating the need for mechanical fasteners. This integration removes the weight of fasteners while maintaining structural connection through the bonded composite material itself.
Solution Approach 2:
The invention extracts and eliminates mechanical fasteners from the assembly process. By using co-curing to join the bag carrier with the composite skin members, the patent removes the unnecessary weight of fasteners while achieving equivalent or superior structural connection.
3Strength
If mechanical fasteners are installed in OML surfaces, then component assembly is achieved, but aerodynamics of the composite structure are disrupted
Solution Approach 1:
The bag carrier is integrated with the composite skin members through co-curing, creating a seamless structure without protruding fasteners in the OML surfaces. This integration maintains smooth aerodynamic surfaces while achieving strong component assembly.
Solution Approach 2:
The invention extracts mechanical fasteners from the OML surfaces entirely. By using co-curing to join components, the patent eliminates the harmful protrusions that would disrupt aerodynamics, maintaining smooth external surfaces.
4Shape
If internal tooling is used for hollow composite structures, then proper shaping and support are achieved, but removal of the tooling after curing becomes time-consuming
Solution Approach 1:
The bag carrier is designed as a disposable or easily removable component. After co-curing with the composite skin members, the bag carrier can be discarded or removed without requiring complex extraction procedures, significantly reducing tooling removal time while maintaining proper hollow structure geometry during curing.
Solution Approach 2:
The bag carrier functions as a temporary support structure that is discarded after serving its purpose. It provides necessary support during curing to achieve proper hollow structure geometry, then can be easily removed or discarded without requiring time-consuming extraction operations.
5Strength
If complex hollow structures are formed using conventional techniques, then structural integrity is achieved, but assembly of internal structures becomes difficult
Solution Approach 1:
The bag carrier and composite skin members are merged into a single co-cured structure, forming complex hollow geometries in one manufacturing operation. This eliminates the need for difficult post-curing assembly of internal structures, as they are all formed together during the co-curing process.
Solution Approach 2:
All internal structures and support elements are preliminarily positioned within the mold around the bag carrier before co-curing. This preliminary arrangement allows complex hollow structures to be formed correctly during the single curing operation, eliminating difficult post-assembly operations.
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 method streamlines the manufacturing process by co-curing composite components, reducing assembly time and weight, while enabling the creation of complex, high-strength structures with improved aerodynamics by integrating the bag carrier within the composite article.
Implementation Method 1
The inflatable mandrel may be inflated to apply an internal compaction pressure on the composite layup against the mold to consolidate the composite layup
Implementation Method 2
Heat may be applied to cure the composite layup
Data Source
AI summary
Provided is a method for forming a co-cured composite article. The method includes: providing a bag carrier; providing a vacuum bag, wherein the vacuum bag at least partially surrounds the bag carrier; providing an outer skin, wherein the outer skin at least partially surrounds the vacuum bag; forming a space between the bag carrier and the outer skin; and providing a filler between the outer skin and the bag carrier.