Shaped Polymer Form for Composite Part Removal
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Solution Overview
Problem
Existing manufacturing processes for composite parts, such as wings and wing shells with twist, taper, and camber, are complex and expensive due to the difficulty in removing molds without damaging either the part or the form, often requiring expensive machining and additional assembly, which increases material waste and reduces structural integrity.
Innovation Solution
A shaped polymer form is created with a glassy state stiffness and a hollow core, allowing a rigid insert to provide rigidity, enabling the form to be drawn out of the composite part in its elastomeric state without relaxing to a different memorized shape, and reused or discarded, eliminating the need for Shape Memory Polymers and costly inflation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid molds are used to manufacture composite parts with complex shapes (twist, taper, camber), then manufacturing precision can be maintained, but the mold cannot be removed from the finished part without damage
Solution Approach 1:
The mold is designed with flexible segments that can move relative to each other, transforming from a rigid structure into a dynamic, adaptable system. The segments can be independently positioned and locked to match complex part geometries, then released to allow easy removal from the finished composite part.
Solution Approach 2:
The mold is divided into multiple separate segments rather than a single rigid piece. Each segment can be independently adjusted, positioned, and removed. This segmentation allows the mold to conform to complex part shapes like twist, taper, and camber while enabling straightforward extraction by simply releasing the segments.
2Manufacturing precision
If expensive machining processes are used to create precise molds, then manufacturing precision is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The mold is divided into multiple standardized segments with simple, repeatable features. Each segment can be manufactured using conventional, low-cost processes rather than expensive custom machining. The segments are assembled together to create the required complex geometry, reducing individual segment complexity while maintaining overall precision.
Solution Approach 2:
The mold segments are designed as universal components that can be used across multiple part geometries and production runs. The same basic segment design can be reconfigured for different twist, taper, and camber requirements, eliminating the need for expensive custom-machined molds for each specific part geometry.
3Ease of manufacture
If the mold is designed to draw (simple geometry), then ease of manufacture is improved, but manufacturing precision for complex shapes (twist, taper, camber) deteriorates
Solution Approach 1:
Complex shapes are achieved by assembling multiple simple segments rather than using a single complex mold piece. Each segment has simple, easy-to-manufacture geometry, but their combination creates the required complex part shapes with high precision through careful positioning and locking mechanisms.
Solution Approach 2:
The mold segments incorporate curved surfaces and rounded transitions that allow them to conform to complex part geometries like twist, taper, and camber. The curved interfaces between segments enable smooth transitions and accurate replication of complex shapes while maintaining simple individual segment designs.
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 manufacturing costs and capital investment by allowing for low-cost production of one-piece composite parts with complex shapes, such as wings, by using inexpensive polymer processes like compression or injection molding, and provides structural integrity without the need for expensive machining or assembly.
Implementation Method 1
A polymer is fabricated into a shaped polymer form and then cured, set, hardened or otherwise solidified. In its elastomeric state the form becomes pliable (without relaxing to a different memorized shape) and can be drawn out of the one-piece composite part.
Data Source
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AI summary
A polymer is formed into the shape of a one-piece composite part and then solidified by curing, setting, hardening or otherwise solidifying the polymer to form a shaped polymer form having a shape that does not draw. Composite material is laid up on the form and solidified to form the composite part. The rigidity required of the form to lay up the composite part can be provided by operating in the polymer form's glassy state, forming the shaped polymer form with a hollow core and placing a rigid insert designed to draw inside the hollow core with the polymer form in its elastomeric state or through a combination of both. In its elastomeric state the form becomes pliable (without relaxing to a different memorized shape) and can be drawn oυt of the one-piece composite part. Because the shape of the form does not draw, the form deforms as it is drawn. If used, the rigid insert is drawn out prior to removing the shaped polymer form. Upon removal, the polymer form in its elastomeric state returns to its original shape. The form may be used once and thrown away or reused to form multiple composite parts of the same shape.