Hollow Reinforcement Structures Intersecting at Angles
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Solution Overview
Problem
Current methods for manufacturing hollow reinforcement structures in the aeronautical field are limited by the inability to simultaneously produce structures intersecting at different angles, leading to increased manufacturing costs and difficulties in removing mandrels after polymerization.
Innovation Solution
A method using a single mandrel with a specific shape to manufacture hollow reinforcement structures that intersect at various angles, combined with a water-soluble mandrel for easy removal and automated processes for efficient lamination and polymerization in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional methods are used to manufacture hollow reinforcement structures, then structures can be produced along parallel directions, but it is impossible to simultaneously manufacture structures along different intersecting directions
Solution Approach 1:
The mandrel is designed with a universal geometry that enables it to define multiple hollow reinforcement structures extending in different directions simultaneously. The mandrel's specific geometric configuration allows it to serve as a template for intersecting structures, making the same mandrel design applicable for creating complex multi-directional reinforcement patterns in a single manufacturing step.
Solution Approach 2:
The mandrel employs a three-dimensional geometric configuration that allows it to define hollow structures in multiple spatial directions at once. By utilizing vertical and horizontal extensions of the mandrel body, the invention transitions from manufacturing structures in a single direction to simultaneously creating intersecting structures in multiple dimensions during one polymerization process.
2Shape
If mandrels are used to manufacture hollow structures, then the hollow structures can be formed with desired shapes, but the mandrel must be removed after polymerization which becomes difficult when structures intersect
Solution Approach 1:
The mandrel is designed with specific geometric features including hollow portions and openings that facilitate the extraction or removal of the mandrel after the polymerization step. The mandrel's geometry allows for easy access and removal mechanisms, solving the problem of difficult mandrel extraction that arises when manufacturing intersecting hollow structures.
3Strength
If trapezoidal or Ω-shaped mandrels are used to manufacture intersecting hollow structures, then the desired structural efficiency is achieved, but further manufacturing effort is required to laminate intersection points increasing costs
Solution Approach 1:
The mandrel geometry is designed to define multiple hollow structures that intersect seamlessly without requiring separate lamination operations at intersection points. By integrating the definition of multiple intersecting structures into a single mandrel design, the invention combines what would otherwise require separate manufacturing steps into one unified process, eliminating additional lamination efforts and reducing manufacturing costs.
Solution Approach 2:
The mandrel is pre-configured with the complete geometric information needed to define all intersecting hollow structures before the polymerization process begins. This preliminary design of the mandrel geometry ensures that all intersection points are accounted for and defined in advance, eliminating the need for subsequent corrective lamination operations at intersection areas.
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 allows for the efficient production of hollow reinforcement structures with intersecting angles in a single step, reducing manufacturing costs and simplifying the process by enabling easy mandrel removal, while enabling automation and application to both flat and curved panels.
Implementation Method 1
a) positioning one mandrel (2) on the surface of a panel (P) in correspondence to each hollow structure (3) to be manufactured; b) laminating at least one composite material layer (4) on top of mandrel (2); c) polymerizing said panel (P) on which said at least one composite material layer (4) is applied
Data Source
Figure 1A~2
Figure 3A~4
Figure 5A~5B
AI summary
Method to manufacture a plurality of hollow reinforcement structures (3) for panels (P) or aerostructures. The method comprises the following consecutive steps: a) positioning at least one mandrel (2) on the surface of a panel (P) in correspondence to each hollow structure (3) to be manufactured; b) laminating at least one composite material layer (4) on top of each mandrel (2); c) polymerizing said panel (P) on which said at least one composite material layer (4) is applied; d) removing said at least one mandrel (2) from the hollow structures ( 3 ). At least two of said hollow reinforcement structures (3) intersect one another a single polymerization step b) is provided for all the hollow reinforcement structures (3).