Multi-State Bladder for Composite Manufacturing Rigidity
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Solution Overview
Problem
Existing inflatable bladders used in composite material fabrication deform under pressure during automated fiber placement, affecting laminate quality, and existing solutions either fail to provide adequate rigidity or require complex and heavy designs that are difficult to implement.
Innovation Solution
An elastomeric apparatus with a housing that can transition between flexible and rigid states through a mechanical actuator, allowing it to maintain rigidity during fiber placement and flexibility during curing, thereby improving part quality without additional installation or removal steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an inflatable bladder is used to maintain internal cavity shape during curing, then the part can resist autoclave pressure, but the bladder deforms under AFP machine pressure during fiber placement
Solution Approach 1:
The bladder incorporates a mechanical actuator system that dynamically changes the stiffness of internal support components between two states: a first state during fiber placement where components are spaced apart allowing flexibility, and a second state during curing where components are positioned to provide rigid support. This dynamic adaptation resolves the contradiction by making the bladder rigid when pressure resistance is needed and flexible when laminate quality is needed.
Solution Approach 2:
The bladder system changes physical parameters (stiffness and structural configuration) between different operational phases. The mechanical actuator modifies the spacing and positioning of internal components, transforming the bladder from a flexible state during fiber placement to a rigid state during curing, thereby addressing both competing requirements.
2Manufacturing precision
If stiff bladders are used to maintain internal cavity shape during fiber placement, then deformation is reduced, but they do not provide even pressure during the cure cycle
Solution Approach 1:
The bladder uses a mechanical actuator to dynamically adjust the configuration of internal support components between two states: during fiber placement, components are spaced apart to allow flexibility and even pressure distribution; during curing, components are positioned to provide rigid support and maintain cavity shape. This dynamic transformation resolves the contradiction between deformation control and pressure distribution.
3Manufacturing precision
If removable rigid bladder inserts are used to provide rigidity during fiber placement, then laminate quality improves, but additional installation and removal operations are required
Solution Approach 1:
The bladder is designed as a multi-functional device that performs both fiber placement support and curing support functions through a single integrated structure. The mechanical actuator enables the same bladder to provide rigidity during fiber placement and maintain cavity shape during curing, eliminating the need for separate removable inserts and reducing operational complexity.
Solution Approach 2:
The bladder dynamically changes its structural properties using an integrated actuator system, transitioning from a flexible state during fiber placement to a rigid state during curing. This eliminates the need for separate removable rigid inserts, reducing device complexity and operational steps while maintaining laminate quality.
4Strength
If solid mandrels are used to provide resistance to deformation during fiber placement, then rigidity is improved, but they are heavy and do not provide even pressure during curing
Solution Approach 1:
The bladder uses a mechanical actuator to dynamically adjust the configuration of internal support components, providing rigidity only when needed during fiber placement. During curing, the components are repositioned to allow flexibility and even pressure distribution. This dynamic adaptation provides the necessary rigidity without the constant weight penalty of solid mandrels.
5Adaptability or versatility
If shape memory polymers are used to change bladder stiffness, then rigidity can be adjusted, but the bladder becomes heavier and more complex to design
Solution Approach 1:
Instead of using complex shape memory polymer materials that require sophisticated design and control systems, the invention employs a mechanical actuator system with movable components that can be positioned between spaced-apart and engaged configurations. This mechanical approach achieves stiffness adjustment with simpler design and reduced weight compared to shape memory polymer solutions.
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
The elastomeric apparatus ensures improved part quality by maintaining rigidity during fiber placement and flexibility during curing, reducing deformation and labor costs, while allowing for efficient removal after the cure cycle.
Implementation Method 1
a rod within the housing extending along a length of the housing, and a plurality of components mounted to the rod, such that in an engaged position of the rod the plurality of components cause the housing to have the rigid surface state, and in a disengaged position of the rod the plurality of components enable the housing to have the flexible surface state
Data Source
AI summary
Within examples, methods and systems for a multi-state bladder or elastomeric apparatus for manufacture of composite material are provided. The elastomeric apparatus includes a housing having a flexible surface state and a rigid surface state, a rod within the housing extending along a length of the housing, and a plurality of components mounted to the rod, such that in an engaged position of the rod the plurality of components cause the housing to have the rigid surface state, and in a disengaged position of the rod the plurality of components enable the housing to have the flexible surface state.