LED Consolidation Roller for Thermoplastic Preforms
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for consolidating preforms in aircraft fuselage construction, such as fiber placement systems and autoclave processes, face challenges with temperature distribution leading to component distortion and high pore content, and incur significant operational and procurement costs.
Innovation Solution
A device comprising a heating element for targeted heat input and a consolidation element for pressure and cooling, allowing for regional heating and pressurization of thermoplastic preforms, eliminating the need for autoclaves and furnaces by using a combination of light-emitting diodes or lasers with a consolidation roller for efficient consolidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If autoclave or furnace processes are used for final consolidation, then complete consolidation of large-surfaced preforms is achieved, but investment and operating costs increase significantly
Solution Approach 1:
The patent applies local heating through LED arrays positioned at specific locations (front, middle, rear) of the consolidation roller to create targeted temperature zones. This allows selective heating of preform regions that require consolidation while avoiding unnecessary heating of other areas, thereby reducing overall energy consumption and operating costs while maintaining consolidation quality.
Solution Approach 2:
The patent replaces the traditional autoclave or furnace system with a consolidation roller that integrates heating elements and pressure application. This mechanical substitution eliminates the need for large, expensive autoclave equipment while achieving the same consolidation function through a more cost-effective mechanism.
2Use of energy by moving object
If laser systems are used for heating in fiber placement systems, then necessary energy input for consolidation is achieved, but temperature distribution problems occur leading to component distortion and elevated pore content
Solution Approach 1:
The heating system is segmented into multiple LED arrays positioned at different locations (front, middle, rear) of the consolidation roller. Each LED array independently heats a specific region of the preform, allowing for uniform temperature distribution across the entire preform surface and preventing the temperature gradients that cause distortion and pore formation.
Solution Approach 2:
The patent changes the heating parameters by using LED technology instead of laser systems, providing more uniform radiant heating. The LED arrays can be controlled to emit specific wavelengths and intensities, creating optimal temperature distribution for thermoplastic matrix consolidation without the focal concentration issues of laser systems.
3Extent of automation
If narrow preforms (3-300 mm per web) are deposited using conventional AFP/ATL systems, then automated fiber placement is achieved, but production time increases significantly to build up complete shell elements
Solution Approach 1:
The consolidation roller serves multiple functions: it applies pressure for consolidation, provides localized heating through integrated LED arrays, and enables processing of much wider preforms (up to several meters) compared to conventional narrow webs. This multi-functionality allows the system to maintain automation while dramatically increasing productivity through wider material deposition.
4Productivity
If thermoset matrix material is used in AFP/ATL systems, then industrial-scale shell component manufacturing is achieved, but downstream autoclave processing is required increasing operational costs
Solution Approach 1:
The patent changes the material parameter by using thermoplastic matrix material instead of thermoset. This parameter change eliminates the need for autoclave curing, as thermoplastics can be consolidated through heating and pressure alone, thereby reducing process complexity and eliminating downstream autoclave processing while maintaining industrial-scale manufacturing capability.
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
Enables the production of high-quality thermoplastic fuselage shells with low pore content, reducing production time and costs, and improving assembly efficiency by allowing wider preforms to be processed, thus simplifying the manufacturing process and lowering investment and operational costs.
Implementation Method 1
a heating element for heating the preform and a consolidation element for exposing the preform to pressure and cooling the preform
Implementation Method 2
a consolidation element for exposing the preform to pressure and cooling the preform
Implementation Method 3
a consolidation element for exposing the preform to pressure and cooling the preform
Data Source
AI summary
A device for consolidating a thermoplastic preform, in particular a carbon fiber thermoplastic preform includes a heating element, e.g., an LED array, for heating the preform and a consolidation element, e.g., a consolidation roller, for exposing the preform to pressure and for cooling the preform. In order to consolidate the preform, the heating element and consolidation element are arranged and movable relative to each other in such a way that the preform can be exposed to pressure and cooled by the consolidation element after heated by means of the heating element.