Mandrel Projections for Composite Acoustic Panel Manufacturing
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Solution Overview
Problem
Existing processes for forming fiber-reinforced composite panels are time-consuming and require high expertise, limiting their efficiency and widespread adoption for noise attenuation applications such as aircraft propulsion systems.
Innovation Solution
A process involving the use of mandrels with projections and ribbon plies made of fibrous material, where the plies are arranged and cured with resin to form a composite core structure, which can be further integrated with skins and perforated to enhance noise attenuation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual laying up processes are used for fiber-reinforced composite panels, then manufacturing precision and structural quality can be achieved, but the process becomes time-consuming and requires high expertise
Solution Approach 1:
The mandrels are pre-configured with projections that define the exact geometry and positioning of the composite structure. The fibrous material is pre-cut into ribbon plies with tabs that align with the mandrel projections, eliminating the need for complex manual shaping and positioning during assembly. This preliminary preparation of components and fixtures enables rapid assembly while maintaining precise geometric control.
Solution Approach 2:
The mandrels with projections serve as intermediary elements that mediate between the fibrous material and the final composite structure. The projections provide a template that guides the placement of ribbon plies, ensuring correct positioning and orientation without requiring expert manual intervention. The mandrels transfer the desired geometry to the composite material through this intermediary role.
2Device complexity
If traditional manual laying up processes are used, then complex composite structures can be formed, but the process requires a high level of expertise
Solution Approach 1:
The mandrels with projections and the tabbed ribbon plies are designed to self-align and self-position during assembly. The tabs on the ribbon plies fit onto the mandrel projections, automatically guiding the material into the correct position without requiring skilled operators to manually align complex geometries. This self-service mechanism reduces the expertise barrier while maintaining the ability to form complex structures.
Solution Approach 2:
The composite structure is segmented into discrete ribbon plies with tabs, each corresponding to specific mandrel projections. This segmentation breaks down the complex laying-up process into simple, repeatable steps where each ply is independently positioned using the mandrel template, reducing the overall complexity of the manufacturing process while enabling complex final structures.
3Weight of moving object
If fiber-reinforced composite materials are used for acoustic panels, then weight reduction is achieved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The fibrous material is pre-impregnated with resin and pre-cut into ribbon plies with tabs before assembly. This preliminary preparation eliminates the need for time-consuming on-site cutting, shaping, and resin application during the manufacturing process. The pre-prepared components can be rapidly assembled onto the mandrels, significantly improving productivity while maintaining the weight benefits of fiber-reinforced composites.
Solution Approach 2:
The resin impregnation of the fibrous material is merged with the molding process itself. The resin-impregnated ribbons are assembled on the mandrels and then cured in place, combining the material preparation and structural forming operations into an integrated process. This merging eliminates separate steps for resin application and molding, improving manufacturing efficiency while producing the desired lightweight composite acoustic panels.
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 process simplifies the manufacturing of fiber-reinforced composite panels, reducing time and expertise requirements while effectively attenuating noise across various applications, including aircraft propulsion systems.
Implementation Method 1
Resin disposed with the first ribbon plies are cured to consolidate the first ribbon plies together and form a fiber-reinforced composite core structure of an acoustic panel
Data Source
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AI summary
A process for manufacturing a composite structure, comprising: providing a plurality of first mandrels (200), each of the first mandrels comprising a base (202) and a plurality of projections (204;204A;204B) arranged longitudinally along and projecting vertically out from the base (202); providing a plurality of second mandrels (238); providing a plurality of first ribbon plies (276;276A), each of the first ribbon plies (276;276A) comprising a sheet of fibrous material; arranging each of the first ribbon plies (276;276A) with a respective one of the first mandrels (200), the arranging of each of the first ribbon plies (276;276A) comprising substantially covering each surface (222;224;226) of each of the projections (204;204A;204B) of one of the first mandrels (200) with a respective one of the first ribbon plies (276;276A); mating each of the second mandrels (238) with a respective one of the first mandrels (200) such that each of the first ribbon plies (276;276A) is sandwiched between a respective one of the first mandrels (200) and a respective one of the second mandrels (238); and curing resin disposed with the first ribbon plies (276;276A) to consolidate the first ribbon plies (276;276A) together and form a fiber-reinforced composite core structure of an acoustic panel (332).