Pigmented Composite Profiles With Knitted Support for Complex Shapes

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Solution Overview

Problem

Existing methods for manufacturing composite material profiles with pigmented coatings face inefficiencies in reducing manufacturing time, particularly when dealing with complex geometries, and are limited by the use of woven fiber structures that restrict application to developable surfaces.

Innovation Solution

The use of a knitted structure for the pigmented layer support, applied simultaneously with the structural fiber plies, allows for the deformation of the pigmented layer to conform to non-developable geometries, reducing manufacturing time by integrating the pigmented layer hardening with the structural fiber hardening process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a pigmented layer is applied to a preform and then deformed, then the manufacturing time is reduced by integrating hardening steps, but the pigmented layer may develop creases on non-developable surfaces

Engineering Contradiction:

Improvemanufacturing timeVSAvoidsurface quality of pigmented layer

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The pigmented layer is divided into two functional components: a support structure (knitted fabric) that provides mechanical strength and flexibility, and a pigmented film that provides the final surface appearance. This segmentation allows each component to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The knitted support structure acts as an intermediary between the pigmented film and the preform. It provides a flexible substrate that can conform to non-developable surfaces while supporting the pigmented film, preventing direct contact between the film and complex geometries that would cause creases.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If a woven fiber structure is used to support the pigmented layer, then the structure provides strength, but it restricts application to developable surfaces only

Engineering Contradiction:

Improvestructural strength of supportVSAvoidapplicability to complex geometries

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid woven fiber structures with flexible knitted fabrics. The knitted structure's inherent flexibility and elasticity allow it to conform to complex, non-developable three-dimensional surfaces while maintaining the necessary mechanical strength to support the pigmented film.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The invention changes the structural parameter of the support from woven to knitted configuration. This parameter change fundamentally alters the mechanical properties, providing both the required strength and the necessary flexibility to adapt to various surface geometries.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the pigmented layer is applied before deformation, then manufacturing time is reduced, but the pigmented layer must withstand deformation stresses that may damage it

Engineering Contradiction:

Improvemanufacturing timeVSAvoidintegrity of pigmented layer

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The pigmented layer is applied to the preform in its flat state before deformation occurs. The knitted support structure is pre-configured to accommodate the subsequent deformation process, allowing the pigmented layer to be applied early in the manufacturing process without compromising its integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The knitted support structure provides a cushioning effect that protects the pigmented film during deformation. The flexible knitted fabric absorbs and distributes deformation stresses, preventing direct stress concentration on the pigmented film that would cause damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 enables the production of composite material profiles with complex geometries efficiently, reducing manufacturing time and ensuring seamless integration of the pigmented layer without creases, even on non-developable surfaces.

Implementation Method 1

at least one surface of the profile is covered with a pigmented coating after the curing stage, promoting the absorption of the wave beam

Methodology Applied

Scientific EffectAbsorption of electromagnetic radiation: Absorption (EM radiation)

Implementation Method 2

the pigmented film and the support structure, pressed together, are baked and deformed simultaneously. The pigmented film is deformed on the already shaped support structure. In one configuration, the pigmented film 42 has a glass transition temperature (Tg) lower than the shaping temperature. Thus, during deformation, the pigmented film 42 softens and can conform to a non-developable three-dimensional shape

Methodology Applied

Scientific EffectThermal deformation: Thermal Expansion

Data Source

PatentEP4691743A1Method for producing a section from a pigmented composite material, section obtained by said method

Publication Date: 2026.02.11 AIRBUS (SAS)

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AI summary

The invention relates to a method for manufacturing a composite material profile comprising a step of obtaining a preform and a step of applying at least one pigmented layer to the preform, the pigmented layer comprising at least one pigmented film and at least one support structure (44) having a knitted structure (44.1). Since the knitted structure (44.1) is flexible, it is possible to obtain profiles with complex geometries. The invention also relates to a profile obtained by such a method and to a stiffened panel comprising at least one such profile.