Metal Sheet Bonding with Flat Cure and Post-Roll Forming
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Solution Overview
Problem
Current methods for bonding metal sheets in aircraft manufacturing result in thick bonds and voids, leading to inefficiencies and structural flaws, and require separate autoclaving due to limited space, which limits the number of assemblies that can be cured at once.
Innovation Solution
Bonding metal sheets and frame members in a flat configuration before rolling them into the desired shape, allowing multiple assemblies to be stacked and cured simultaneously in an autoclave, followed by roll forming to achieve the final curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal sheets are bonded after rolling into curved shapes, then the final curved shape is achieved, but the autoclave space is insufficient and only one assembly can be cured at a time
Solution Approach 1:
The patent applies preliminary action by bonding metal sheets and frame members in a flat configuration before rolling them into curved shapes. This allows multiple assemblies to be stacked and cured simultaneously in the autoclave, maximizing space utilization and productivity. After curing, the assemblies are then roll-formed to achieve the final curved geometry.
2Productivity
If metal sheets are bonded in flat configuration before rolling, then multiple assemblies can be cured simultaneously, but the bonding surface area is reduced
Solution Approach 1:
The patent resolves this contradiction by transitioning to another dimension - stacking multiple flat assemblies vertically in the autoclave. This allows the bonding process to occur simultaneously across multiple assemblies in the vertical dimension while maintaining adequate bonding surface area on each individual assembly.
3Manufacturing precision
If metal sheets are bonded after rolling, then the curved shape is maintained during bonding, but thick bonds and voids are formed
Solution Approach 1:
The patent applies preliminary action by performing the bonding operation in a flat configuration before rolling. This ensures optimal bond quality without voids or thick bonds, as the flat configuration allows for uniform adhesive distribution and consistent pressure during curing. The rolling operation is performed after bonding to achieve the final curved shape without compromising bond integrity.
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 reduces flaws and improves efficiency by enabling multiple metal sheet assemblies to be bonded and cured simultaneously, expediting the process and ensuring proper alignment of radii.
Implementation Method 1
autoclaving the stack, thereby bonding the first frame member to the first metal sheet
Implementation Method 2
form rolling each of the flat metal sheet assemblies to provide at least two curved metal sheet assemblies
Data Source
AI summary
A method for metal bonding includes providing at least two metal sheet assemblies wherein each metal sheet assembly includes at least one frame member and a flat metal sheet. Each frame member is placed onto the flat metal sheet to form a metal sheet assembly. The metal sheet assemblies are stacked upon one another to form a sheet stack, and the sheet stack is autoclaved to allow for bonding to occur between the flat metal sheet and the frame member of each metal sheet assembly. The sheet stack is removed from the autoclave and each metal sheet assembly is unstacked from the sheet stack. Each bonded metal sheet assembly then undergoes a roll forming process to provide at a curved metal sheet assembly.