Roll Forming Thermoplastic Composites for Large Curved Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming thermoplastic composite material parts with curvature and non-planar features, such as stiffening elements for aircraft, face challenges in scalability and difficulty in forming complex shapes.
Innovation Solution
A toolless apparatus and method using roll forming techniques with a combination of thermoplastic composite material spools, rollers, welding rollers, an oven, and pinch rollers to create a curvature in large-scale parts by heating and compressing a metal composite material laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If stamp forming is used to form thermoplastic composite parts, then parts with curvature can be formed, but the tools and presses do not scale well to forming larger parts
Solution Approach 1:
The forming process is segmented into multiple sequential rolling operations rather than a single stamping action. The material passes through multiple rollers that progressively impart curvature, allowing the process to scale to larger parts by adding more rollers or adjusting their positions along the forming line.
Solution Approach 2:
The system transitions from static stamping tools to dynamic rolling elements that can adjust their position, pressure, and curvature radius. The rollers can be moved along the material width and length, enabling flexible forming of various part sizes and curvature profiles without requiring completely different tooling.
2Adaptability or versatility
If continuous compression molding is used to form large scale parts, then scalability is improved, but difficulty forming parts with non-planar or curved features increases
Solution Approach 1:
The system employs curved and contoured rollers instead of flat compression surfaces. These rollers are specifically designed with varying radii of curvature to impart the desired non-planar features and complex shapes to the thermoplastic composite parts while maintaining continuous forward motion for scalability.
Solution Approach 2:
Different sections of the rolling system have rollers with locally optimized curvature and pressure characteristics. Specific rollers are designed to create particular geometric features at specific locations along the material, allowing complex multi-curved features to be formed in a single pass while maintaining production efficiency.
3Adaptability or versatility
If multi temperature and variable section tool set is used for continuous compression molding, then large scale parts can be formed, but the complexity of the tool set increases
Solution Approach 1:
The rolling system uses a universal set of rollers that can perform multiple functions by adjusting their position, rotation speed, and applied pressure. The same rollers can create different curvature profiles and form various part geometries, eliminating the need for completely different tool sets for different part configurations.
Solution Approach 2:
The system replaces static multi-temperature tooling with dynamic rollers that can be independently controlled. Each roller's temperature, speed, and position can be adjusted in real-time to achieve different forming conditions, reducing the need for physical tool changes while maintaining versatility.
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
Enables the fabrication of thermoplastic composite material parts with complex curvatures and non-planar features, particularly stiffening elements for aircraft, by imparting a controlled curvature and compaction, addressing scalability issues of previous methods.
Implementation Method 1
The oven is configured to heat the metal composite material laminate
Implementation Method 2
The forming roller is positioned within the oven and is configured to receive the metal composite material laminate and to selectively move along one or more axes in order to impart a curvature on the metal composite material laminate
Implementation Method 3
The pinch rollers are configured to receive the metal composite material laminate from the forming roller, to pull the metal composite material laminate, and to output the metal composite material laminate in a heated and compressed state
Data Source
AI summary
An apparatus for roll forming thermoplastic composites comprises a plurality of thermoplastic composite material spools, a plurality of thermoplastic composite material rollers, a plurality of sheet metal spools, a plurality of welding rollers, an oven, a forming roller, a pair of pinch rollers. The thermoplastic composite material spools retain plies of thermoplastic composite material. The plies flow through the thermoplastic composite material rollers to form a layup. The sheet metal spools retain metal sheets. The metal sheets and the layup flow through the welding rollers to form a metal composite material laminate. The oven heats the metal composite material laminate. The forming roller imparts a curvature to the metal composite material laminate. The pinch rollers receive the metal composite material laminate from the forming roller, pull the metal composite material laminate, and output the metal composite material laminate in a heated and compressed state.