Pre-patterned Layup Kit for Automated Composite Airframe Manufacturing
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Solution Overview
Problem
Current methods for applying composite materials in aircraft production are inefficient, labor-intensive, and wasteful, particularly when dealing with complex airframe features, leading to increased manufacturing costs and production time due to the need for frequent repositioning of AFP mandrels and manual application errors.
Innovation Solution
A pre-patterned layup kit is manufactured with a flexible carrier and layup release layer, where pre-patterned laminae are compacted and indexed to accommodate specific airframe features, allowing for efficient automated application and minimizing discontinuous AFP mandrel operation and manual layup application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional AFP mandrels are used for composite material placement, then automated fiber placement can be achieved, but frequent stopping and repositioning is required for complex airframe features
Solution Approach 1:
The patent pre-patterns the composite material layup on a flexible carrier before application to the airframe. This preliminary arrangement of laminae with correct orientations and positions eliminates the need for frequent AFP mandrel stopping and repositioning during application, as the entire pre-patterned assembly can be applied in fewer continuous operations
Solution Approach 2:
The patent divides the composite structure into a pre-patterned layup kit that can be applied as a unit, and separates the flexible carrier from the airframe surface. This segmentation allows the layup to be prepared independently and applied efficiently without continuous AFP mandrel operation for each individual layer
2Adaptability or versatility
If manual application methods are used for reinforcement layers, then complex airframe features can be accommodated, but labor intensity and application errors increase
Solution Approach 1:
The reinforcement layers are pre-patterned on the flexible carrier with correct orientations, positions, and configurations tailored to specific airframe features. This preliminary preparation eliminates the need for complex manual cutting, trimming, and positioning operations during application, reducing both labor intensity and error potential
Solution Approach 2:
The flexible carrier acts as an intermediary that holds the pre-patterned laminae in the correct configuration. This intermediary allows the complex multi-layer reinforcement structure to be transferred as a unified assembly to the airframe, avoiding the need for operators to manually position and bond each layer individually
3Quantity of substance
If conventional layup kits are applied to airframes, then composite materials can be placed, but material waste and application time increase
Solution Approach 1:
The layup kit is pre-patterned with the exact configuration, orientation, and positioning of laminae required for the specific airframe region. This precise preliminary arrangement ensures that composite materials are placed only where needed with correct orientations, eliminating material waste from incorrect placement, trimming, and rework
Solution Approach 2:
The patent applies different lamina orientations and configurations at different locations on the airframe according to specific structural requirements. The pre-patterned layup kit ensures each local region receives the appropriate material orientation and layering, optimizing material usage and eliminating waste from generic or incorrect material application
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 material waste and application time by enabling precise, automated application of composite materials to complex airframe geometries, enhancing manufacturing efficiency and reducing errors.
Implementation Method 1
compact the layup release layer and the flexible carrier in a vacuum
Implementation Method 2
perform a second compacting of the pre-patterned layup, the layup release layer, and the flexible carrier in a vacuum
Data Source
Figure 1(i)
Figure 1(ii)
Figure 2
AI summary
A pre-patterned layup kit with layup patterned to accommodate an airframe topological feature, trimmed to fit a preselected target region of a layup structure, and conformed to the target region contour. The kit can be fabricated in advance of airframe manufacture and stored until use. The kit includes a flexible carrier upon which the layup is laid, and a release layer between the layup and the carrier. The layup has multiple laminae oriented to an carrier indexing element, and indexed to the target region thereby. A kit manufacturing method includes preparing the laminae constituent of the layup, preparing the carrier, and laying down the laminae on the carrier to make the kit. The kit can be compacted, inspected, and prepared for storage. The layup can be fabricated of a pre-patterned lamina or multiple laminae that are shaped and trimmed to accommodate an airframe topological feature.