Portable Composite Processing Vessel for Aircraft Components
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Solution Overview
Problem
Conventional autoclave and oven processing techniques for large composite structures, such as aircraft components, are inefficient due to high costs, long cycle times, and the need for large equipment and consumable materials.
Innovation Solution
A processing apparatus comprising a mandrel-tool and tooling assembly that forms a sealed vessel to apply pressure and heat directly to the composite structure, reducing the size and energy requirements of the processing equipment and eliminating the need for consumable materials like vacuum bagging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but the equipment requires significant floor space and has large volume
Solution Approach 1:
The processing system is segmented into a portable processing unit that can be moved to the composite structure, rather than requiring the structure to be placed in a large fixed autoclave or oven. This segmentation allows the processing equipment to be divided into smaller, more manageable components that occupy less floor space.
Solution Approach 2:
The processing function is extracted from a large stationary autoclave/oven environment and transferred to a portable unit that applies pressure and heat directly at the workpiece location. This extraction eliminates the need for huge volumes of heated gas and large equipment infrastructure.
2Manufacturing precision
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but the equipment requires significant time to heat up and cool down between cycles
Solution Approach 1:
The portable processing unit applies heat and pressure locally directly to the composite structure rather than heating a large volume of gas in a massive autoclave. This localized approach significantly reduces the thermal mass that needs to be heated and cooled, thereby reducing cycle time.
Solution Approach 2:
The processing function is extracted from a large thermal mass environment (conventional autoclave/oven) and performed in a compact portable unit with minimal thermal mass, enabling faster heating and cooling cycles.
3Manufacturing precision
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but consumable materials such as bagging are required
Solution Approach 1:
The portable processing unit integrates vacuum generation and pressure application capabilities directly into the system, eliminating the need for external consumable bagging materials. The system serves itself by providing all necessary processing functions through integrated components.
Solution Approach 2:
The portable processing unit acts as an intermediary between the operator and the composite structure, providing integrated vacuum and pressure control without requiring intermediate consumable materials like vacuum bags or compression blankets.
4Manufacturing precision
If conventional autoclave and oven processing techniques are used, then composite structures can be processed, but huge volumes of heated gas are required
Solution Approach 1:
The portable processing unit applies heat and pressure locally directly to the composite structure rather than heating huge volumes of gas in a large autoclave chamber. This localized thermal application dramatically reduces the quantity of gas that needs to be heated and circulated.
Solution Approach 2:
The processing function is extracted from a large-volume gas heating system and performed in a compact unit that applies thermal energy directly to the workpiece, eliminating the need for huge volumes of heated gas.
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 reduces processing costs and cycle times, increases throughput, and allows for more flexible facility layouts by minimizing equipment size and energy consumption.
Implementation Method 1
the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel, configured to apply at least one of pressure and heat to the composite structure
Implementation Method 2
the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel, configured to apply at least one of pressure and heat to the composite structure
Data Source
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AI summary
An apparatus (100) for processing a composite structure (102) includes a first processing-tool (104) and a second processing-tool (106) that are movable between an open position, in which the first processing-tool (104) and the second processing-tool (106) are separated from each other, and a closed position, in which the first processing-tool and the second processing-tool are configured to be sealed to each other. In the closed position, the first processing-tool and the second processing-tool are configured to be sealed to a mandrel-tool (112), located between the first processing-tool and the second processing-tool and supporting the composite structure. In the closed position, the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel (114), configured to apply at least one of pressure and heat to the composite structure.