Pre-assembled Auxiliary Strip for Composite Vacuum Forming
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Solution Overview
Problem
Manual cutting of auxiliary materials for vacuum build-up in structural component manufacturing introduces errors and reduces reproducibility and process robustness due to the need for individual rolls to be cut to size directly on the device.
Innovation Solution
A pre-assembled auxiliary material strip consisting of a textile ventilation fleece and a separating film, where the separating film is wider than the fleece, is used, allowing for precise placement and self-centering, and eliminating the need for manual cutting, with the separating film overlapping on both sides of the fleece to prevent resin penetration and ensure a vacuum-tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual cutting of auxiliary materials is performed directly on the device, then flexibility in adapting to different component sizes is improved, but manufacturing precision and reproducibility deteriorate due to cutting errors
Solution Approach 1:
The auxiliary materials (ventilation fleece and separating film) are pre-cut to standard sizes before being transported to the manufacturing device. This preliminary cutting action is performed in a controlled environment using automated cutting equipment, ensuring high precision and eliminating manual cutting errors at the device location.
Solution Approach 2:
A pre-assembled auxiliary material strip is introduced as an intermediary component that combines multiple layers (ventilation fleece and separating film) in a fixed configuration. This strip serves as a standardized unit that can be easily positioned and attached to the device, eliminating the need for on-site cutting while maintaining adaptability through standardized sizing.
2Adaptability or versatility
If multiple separate auxiliary materials are used, then functionality is improved, but device complexity increases due to multiple assembly steps
Solution Approach 1:
The ventilation fleece and separating film are merged into a single pre-assembled strip structure. These two functional layers are bonded together in a fixed configuration, creating one integrated component that performs both functions simultaneously. This merging eliminates the need for separate assembly steps and reduces device complexity.
Solution Approach 2:
The auxiliary materials are pre-assembled into a complete strip structure before being transported to the device. All necessary layers are combined in advance, so that during manufacturing, only a single placement and attachment operation is required, rather than assembling multiple separate components on-site.
3Adaptability or versatility
If individual auxiliary materials are assembled on the device, then adaptability to specific component requirements is improved, but productivity deteriorates due to time-consuming assembly
Solution Approach 1:
The auxiliary material strip is completely prepared in advance, including cutting, layer assembly, and bonding of all components. This preliminary preparation is performed in a dedicated pre-assembly station, allowing the manufacturing device to simply receive and attach the complete strip, thereby eliminating time-consuming assembly operations during the manufacturing cycle.
Solution Approach 2:
The pre-assembled auxiliary material strip acts as an intermediary that encapsulates all customization decisions made during the design phase. Standardized strip dimensions and configurations allow for quick selection and attachment, eliminating the need for time-consuming on-site assembly while still providing adaptability through standardized options.
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 solution simplifies handling, reduces assembly errors, and enhances reproducibility by allowing for quick and precise placement of auxiliary components, ensuring a robust and uniform negative pressure distribution across the component surface.
Implementation Method 1
The device receiving the semifinished fiber product must be sealed against the ambient pressure with a vacuum film
Implementation Method 2
The resin in the device reacts under increased temperature and vacuum and the structural component is created. The initially liquid resin is brought into the semi-finished fiber product by means of negative pressure
Implementation Method 3
these dry semi-finished fiber products are impregnated with the resin as a matrix material and then cured. The initially liquid resin is brought into the semi-finished fiber product by means of negative pressure
Implementation Method 4
The resin in the device reacts under increased temperature and vacuum and the structural component is created
Data Source
Figure 1~3
AI summary
The invention relates to a device for the primary forming of an integral structural component made of a fiber composite material reinforced with stringers (7a, 7b) for an aircraft, comprising at least one molded part (2) forming a mounting surface (1) for creating an outer or inner surface of the structural component, on which at least one channel (3) for evacuating the structural component, which is covered with a vacuum film (4) and consists of a skin laminate (6) and several spaced-apart stringers (7a, 7b), is arranged, wherein at least surface sections (8) between adjacent stringers (7a, 7b) are covered with an auxiliary material strip, which consists of a textile ventilation fleece (9) that comes into contact with the vacuum film (4) and a pre-assembled separating film (10) firmly bonded thereto, the width (BF) of which is greater than or equal to the width (BV) of the ventilation fleece (9).