Composite Panel Insert Molding and Edge Filling Automation
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Solution Overview
Problem
The installation of inserts in composite panels for vehicles, such as aircraft, is inefficient and labor-intensive, requiring multiple machines and significant curing times for adhesives, and the edges often require manual smoothing after machining.
Innovation Solution
A method involving a panel construction machine that extrudes plastic material to surround inserts and edges, using a deployable pin to grip the inserts during injection, and a multi-outlet turret to automate the process, reducing manual labor and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple machines are used for insert installation and through-hole machining, then the inserts can be properly installed and holes machined, but manufacturing efficiency is impeded and manpower requirements increase
Solution Approach 1:
The patent combines multiple separate machines (insert installation machine, through-hole machining machine, adhesive application machine) into a single integrated automated panel construction system. This merging eliminates the need for multiple separate machines and reduces manpower requirements while maintaining all necessary functions.
Solution Approach 2:
The automated panel construction system is designed to perform multiple functions: inserting inserts into panels, machining through-holes, applying adhesives, and curing. This multi-functional system replaces several specialized machines with one universal apparatus that handles all construction operations.
2Reliability
If adhesives are applied to inserts and surrounding cavities, then inserts can be secured in place, but significant curing time is required
Solution Approach 1:
The system applies adhesives to inserts and cavities as part of the automated construction process before panel assembly, ensuring proper adhesive placement and distribution. This preliminary action optimizes the bonding process and reduces the time required for effective curing while maintaining secure insert attachment.
Solution Approach 2:
The automated system performs adhesive application, insert insertion, and panel assembly in a continuous automated sequence without interruption. This continuous process eliminates idle time between operations and maintains constant productive action, reducing overall manufacturing time while ensuring proper adhesive curing conditions.
3Manufacturing precision
If manual filler application is used on rough machined edges, then edges can be smoothed for further machining, but manual labor and time are required
Solution Approach 1:
The automated panel construction system incorporates self-service capabilities where the machine automatically performs edge filling and smoothing operations without manual intervention. The system applies filler material to rough edges and automates the smoothing process, eliminating the need for manual filler application while maintaining edge quality for subsequent machining operations.
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 method enhances manufacturing efficiency and reduces costs by automating the insertion of inserts and smoothing of edges, allowing for faster and more cost-effective production of panels.
Implementation Method 1
extruding a plastic material and injecting the extruded plastic material into at least one of an edge of the panel and an insert cavity of the panel
Data Source
AI summary
A method of manufacturing a panel is disclosed, which may include extruding a plastic material and injecting the extruded plastic material into at least one of an edge of the panel and an insert cavity of the panel. A panel construction machine is also disclosed, which may include a plastic extruder configured to extrude a plastic material and an injection molding nozzle configured to inject the extruded plastic material into at least one of an edge of a panel and an insert cavity of the panel.