Radius Filler Kit for Composite Stringer Placement
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Solution Overview
Problem
The current manual application of radius fillers in composite layups is time-consuming and inefficient, leading to inconsistencies and increased manpower costs, as well as additional compaction steps and potential radii buckling.
Innovation Solution
A method and apparatus for positioning and applying a plurality of segments of radius filler onto a forming tool, followed by a single placement step onto a stringer, using a radius filler kit with a vacuum bag system to apply compression and adhesion, allowing for simultaneous application and compaction of multiple segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If radius fillers are applied individually by hand to a composite layup, then each filler can be precisely positioned, but the application process becomes time-consuming and increases manpower requirements
Solution Approach 1:
The radius filler application is segmented into multiple independent filler units that are pre-positioned on a carrier material in a single kit. This allows multiple segments to be applied simultaneously in one placement operation, dramatically improving productivity while maintaining precise positioning through the pre-configured carrier material layout.
Solution Approach 2:
The radius fillers are pre-positioned and pre-configured on the carrier material before application to the composite layup. This preliminary action of positioning multiple fillers in their final locations on the carrier material eliminates the need for repeated manual positioning operations, thereby increasing application speed while preserving positioning accuracy.
2Manufacturing precision
If multiple compaction steps are used to apply radius fillers, then adequate compression is achieved, but the process becomes more complex and time-consuming
Solution Approach 1:
The application and compaction operations are merged into a single integrated step. The carrier material serves dual functions as both the placement medium and the compaction medium, eliminating the need for separate compaction steps. This reduces process complexity while maintaining adequate compaction quality through the vacuum bag system that applies uniform pressure.
Solution Approach 2:
The vacuum bag system serves multiple functions simultaneously: it applies compression force to compact the radius fillers, maintains their positioned configuration, and facilitates their transfer to the composite layup. This multi-functionality eliminates the need for separate compaction equipment and steps, simplifying the overall process while ensuring proper compaction.
3Ease of operation
If manual application methods are used for radius fillers, then flexibility in handling is maintained, but manufacturing time and manpower costs increase
Solution Approach 1:
Multiple radius fillers are pre-configured and pre-positioned on the carrier material in their final intended locations before the application process. This preliminary configuration allows the entire kit to be handled as a single unit with one placement motion, maintaining operational simplicity and flexibility while dramatically reducing the time and manpower required compared to individual manual 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 approach reduces application time, minimizes inconsistencies, and decreases the number of compaction steps, enhancing the efficiency and accuracy of radius filler placement while reducing manpower and manufacturing time.
Implementation Method 1
a vacuum is applied to the plurality of segments of radius filler and the stringer to apply the compression force to the plurality of segments of radius filler
Data Source
AI summary
A plurality of segments of radius filler is positioned onto a radius filler forming tool. The plurality of segments of radius filler is applied to a stringer in a single placement step.