Jamming Applicator Assembly for Composite Compaction Pressure
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Solution Overview
Problem
Existing compaction systems for laminated composite structures, such as in the aerospace industry, fail to account for variability in material thickness and often apply insufficient pressure during compression, leading to suboptimal formation of composite airframes and structural members.
Innovation Solution
The applicator system includes a jamming material within membranes that can be adjusted between a vacuum-jammed and positive-pressure configuration, allowing for deformability and rigidity control, enabling precise pressure application and shape retention on a forming tool, with optional heat application for forming composite structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a vacuum bag is placed over the structure and sealed under pressure, then the structure is compressed, but the system fails to account for variability in material thickness and applies insufficient pressure
Solution Approach 1:
The applicator system transitions from a static rigid structure to a dynamic system that can change its mechanical properties. The granular material inside the applicator allows it to dynamically adjust between rigid and compliant states based on vacuum pressure, enabling it to adapt to varying material thicknesses while maintaining sufficient compression force.
Solution Approach 2:
The system changes the physical state and mechanical parameters of the applicator by applying vacuum pressure. This causes the granular material to transition from a loose state to a jammed rigid state, fundamentally altering the applicator's stiffness and pressure transmission characteristics to match the forming requirements.
2Force
If a shaped metallic compaction tool is used to press the structure, then pressure is applied, but the system cannot adapt to material thickness variability
Solution Approach 1:
The applicator system allows different regions to have different mechanical properties through the compliant granular material. Each location can independently adapt its local density and rigidity based on the underlying material thickness, providing localized pressure adjustment while maintaining overall structural integrity.
Solution Approach 2:
The system transitions from a statically rigid metallic tool to a dynamically adaptable applicator. The granular material enables the applicator to change its mechanical compliance in real-time based on vacuum pressure, allowing it to conform to varying material thicknesses while still delivering sufficient compression force.
3Manufacturing precision
If the applicator is made rigid to hold shape, then pressure application is consistent, but the applicator cannot deform to accommodate the receiving surface
Solution Approach 1:
The applicator system resolves the contradiction between rigidity and deformability by making both states available dynamically. Under vacuum, the granular material jams to create a rigid structure for precise pressure application. When vacuum is released, the material becomes compliant, allowing the applicator to deform and conform to the receiving surface geometry.
Solution Approach 2:
The system changes the mechanical parameter of the applicator's rigidity by controlling vacuum pressure. This single parameter change enables the applicator to transition between compliant and rigid states, allowing it to first deform to match the receiving surface and then maintain consistent pressure during the forming 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
This solution ensures consistent and sufficient pressure application, accommodating material thickness variability, and enhances the formation of composite structures by allowing the applicator to be deformable in an unjammed state and rigid in a jammed state, improving the quality and accuracy of composite airframes and structural members.
Implementation Method 1
an applicator that is jammed under vacuum and unjammed under positive pressure, such that the applicator is, in an unjammed configuration, deformable about a receiving surface of a forming tool and, in a jammed configuration, holds the shape of the forming tool
Implementation Method 2
The applicator is configured to be jammed under vacuum and unjammed under positive pressure
Implementation Method 3
jammed under vacuum and unjammed under positive pressure
Data Source
AI summary
An applicator assembly for applying pressure to a composite structure includes an external frame, an applicator casing disposed substantially within the external frame, and an applicator disposed substantially within the applicator casing. The applicator casing includes a first membrane, and a first jamming material disposed within the first membrane. The applicator includes a second membrane, and a second jamming material disposed within said second membrane.