Perforated Composite Plies for Volatile Evacuation
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Solution Overview
Problem
Current methods for manufacturing composite aircraft components using composite materials are inefficient in terms of time and cost, often resulting in porosity and reduced quality due to the need for prolonged vacuum processing and limited ply stack thickness, which increases production time and scrap rates.
Innovation Solution
The method involves forming a ply stack with partially perforated uncured composite plies, allowing for both through-the-thickness and edge bleeding evacuation of volatiles during compacting, which reduces processing time and porosity, enabling the production of high-quality composite structures with increased ply count per cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional vacuum processing methods are used for composite structure manufacturing, then porosity is reduced, but processing time is significantly prolonged
Solution Approach 1:
The patent divides the evacuation process into two segments: through-the-thickness evacuation using perforations and edge bleeding evacuation along the edges. This segmentation allows volatiles to be removed through multiple pathways simultaneously, reducing the time required while maintaining porosity reduction effectiveness
Solution Approach 2:
The patent introduces a new dimension for volatile evacuation by creating perforations that extend through the thickness of the ply stack. This adds a through-thickness evacuation pathway to the traditional edge bleeding method, enabling faster volatile removal without compromising porosity control
2Strength
If ply stack thickness is increased to improve structural integrity, then manufacturing complexity increases, but production time and scrap rates increase
Solution Approach 1:
The patent segments the thick ply stack into multiple layers with perforations distributed throughout. This allows efficient volatile evacuation from each layer, enabling the manufacturing of thick, structurally sound composite structures without proportionally increasing processing time or scrap rates
Solution Approach 2:
The patent intentionally creates a porous structure within the ply stack by incorporating perforations through the thickness. This controlled porosity facilitates volatile removal while maintaining the overall structural integrity of the thick composite structure
3Length of stationary object
If multiple uncured composite plies are stacked to achieve desired thickness, then manufacturing complexity increases, but volatile evacuation becomes less effective
Solution Approach 1:
The patent segments the multi-ply stack by introducing perforations at regular intervals through the thickness. This segmentation creates multiple evacuation pathways, maintaining effective volatile removal even as the number of plies and overall thickness increase
Solution Approach 2:
The patent adds a through-thickness evacuation dimension to the traditional planar edge bleeding approach. By creating perforations that penetrate through multiple plies, the system maintains effective volatile evacuation efficiency regardless of the number of plies stacked
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 approach significantly reduces debulking/compaction time and porosity, allowing for the efficient manufacture of high-strength, high-quality composite structures with increased ply count per processing cycle, thereby lowering production costs and time.
Implementation Method 1
increasing a vacuum level within the bag to increase external pressure on the bag and the composite structure
Implementation Method 2
increasing a vacuum level within the bag to increase external pressure on the bag and the composite structure
Implementation Method 3
The plurality of perforations may provide paths for volatiles to be removed through the thickness of the one or more uncured composite ply of the ply stack during the compacting
Data Source
AI summary
A method is provided in one example embodiment and may include forming a ply stack comprising a plurality of uncured composite plies, wherein one or more uncured composite ply of the plurality of uncured composite plies comprises a plurality of perforations that extend, at least partially, through a thickness of the one or more uncured composite ply; and compacting the ply stack to form a composite structure. The plurality of perforations may provide paths for volatiles to be removed through the thickness of the one or more uncured composite ply of the ply stack during the compacting. Volatiles may also be removed through edges of the ply stack during the compacting. In some instances, all uncured composite plies of the ply stack may include a plurality of perforations that extend, at least partially, through the thickness of each uncured composite ply.