Scroll Deployment for Composite Preform Compaction

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Solution Overview

Problem

The challenge lies in securely placing and compacting large, unwieldy preforms of composite materials, such as carbon fiber, onto complex surfaces without them peeling off or shifting before hardening, especially when using vacuum bag curing techniques, which requires a method to rapidly and effectively secure preforms to complex surfaces during the layup process.

Innovation Solution

A scroll deployment system that uses a permeable layer with an impermeable membrane, deployed via an end effector and spindles, applies negative pressure to compact the preform onto a rigid tool, forming a suction hold without the need for tape or sealants, allowing for rapid compaction and subsequent vacuum bagging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional vacuum bag curing techniques are used to harden preforms, then the preform can be hardened into a composite part, but it is difficult to secure the vacuum bag around the preform before the preform peels away or shifts from the complex surface

Engineering Contradiction:

Improvepreform placement stabilityVSAvoidvacuum bag securing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The scroll is deployed and secured to the preform surface before the vacuum bag is applied. The scroll creates initial adhesion and maintains preform position during the subsequent vacuum bagging process, preventing peeling and shifting that would occur if vacuum bagging alone were used from the start

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The scroll acts as an intermediary element between the preform and the vacuum bag. It provides a secure attachment mechanism that allows the vacuum bag to be properly sealed and maintained without directly compromising the preform's adhesion to the complex surface

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the entire layup is completed prior to vacuum bag application to avoid contact with uncured material, then contamination is prevented, but the process time is significantly increased

Engineering Contradiction:

Improvematerial contamination preventionVSAvoidlayup process speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The scroll serves as an intermediary barrier that allows the vacuum bag to be applied without directly contacting the uncured preform material. This enables the vacuum bag sealing process to occur while maintaining material contamination prevention, thus improving productivity without sacrificing reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The scroll is deployed and secured as a preliminary step before vacuum bagging. This preliminary action creates a protective interface that allows subsequent vacuum bag application without contaminating the uncured material, enabling faster process times while maintaining contamination prevention

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If large preforms are laid up onto complex surfaces without additional securing mechanisms, then the process is simpler, but the preform is incapable of supporting itself and may peel off or shift before hardening

Engineering Contradiction:

Improvelayup operation simplicityVSAvoidpreform position stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The scroll is deployed as a flexible thin film structure that conforms to the complex surface geometry and wraps around the preform. This flexible structure provides secure attachment and position maintenance without requiring complex rigid securing mechanisms, thus maintaining ease of operation while improving reliability

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The scroll acts as an intermediary securing mechanism between the preform and the complex surface. It provides the necessary adhesion and position stability that the preform cannot achieve on its own, while still allowing for relatively simple deployment and operation

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables secure, tapeless compaction of preforms onto complex surfaces, enhancing production speed and reducing labor by ensuring accurate placement and preventing preform shifting during the hardening process, while allowing for efficient vacuum bagging.

Implementation Method 1

The scroll includes a permeable layer that enables airflow

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

applying a negative pressure to the scroll that offsets air leaks between the scroll and the object, thereby forming a suction hold that compacts the object onto the rigid tool

Methodology Applied

Scientific EffectVacuum suction: Suction

Implementation Method 3

an impermeable membrane that contacts the permeable layer

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20240308158A1Scrolls that vacuum secure objects to complex surfaces

Publication Date: 2024.09.19 THE BOEING CO

AI summary

Embodiments include apparatus for compacting an object onto a rigid tool by applying a negative pressure while the scroll of material overlays the object. The apparatus comprises one or more spindles and a scroll of material that is stored on the one or more spindles. The scroll of material comprises a permeable layer and an impermeable membrane wherein the impermeable membrane contacts the permeable layer and may extend beyond a perimeter of the permeable layer.