Smart Bladder Curing Tool for Composite Structures
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Solution Overview
Problem
Current methods for manufacturing composite aircraft structures, such as unitized composite wings, are complex and costly, requiring multiple steps and autoclave processing, which increases time and material waste, and necessitates a high number of fasteners and assembly time.
Innovation Solution
A composite structure manufacturing system utilizing a heating system, smart bladders, and a frame to form a curing tool that generates a thermal profile for curing composite structures without the need for autoclave processing, allowing for co-curing of components without direct attachment, thereby reducing rework and material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If autoclave processing is used for curing composite structures, then curing reliability is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent extracts the heating and curing function from the autoclave environment and implements it directly within the mold cavity using integrated heating elements. This allows curing to occur in-place during molding without requiring subsequent autoclave processing, thereby reducing manufacturing time while maintaining curing reliability through direct thermal control at the composite material interface.
Solution Approach 2:
The patent merges the molding process and curing process into a single integrated operation. By incorporating heating elements directly into the mold and applying heat during the molding cycle, the composite structure is cured simultaneously with formation, eliminating the need for separate autoclave processing and reducing overall manufacturing time.
2Manufacturing precision
If multiple processing steps are used for manufacturing unitized composite structures, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple processing steps (molding and curing) into a single integrated process. The mold includes integrated heating elements that enable curing to occur during the molding cycle itself, reducing the number of separate processing steps and equipment needed while maintaining structural precision through controlled in-situ curing.
Solution Approach 2:
The mold system is designed with multi-functionality, serving both as the forming tool and the curing apparatus. The heating elements integrated into the mold allow it to perform both shaping and thermal curing functions, simplifying the overall manufacturing system by eliminating dedicated autoclave equipment while maintaining manufacturing precision.
3Strength
If components are assembled with multiple fasteners, then structural strength is improved, but assembly time and weight increase
Solution Approach 1:
The patent merges multiple separate composite components into a single unitized structure through co-curing. By molding multiple components (such as wing panels, spars, and ribs) together in a single mold cavity with integrated heating, the components become structurally integrated without requiring fasteners, thereby reducing assembly time and fastener weight while maintaining structural strength through continuous composite material bonding.
4Productivity
If complex tooling is used for co-curing components, then manufacturing efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple separate molds and curing processes into a single unitized mold system. The mold is designed to accommodate multiple composite components simultaneously and includes integrated heating elements for co-curing, thereby improving manufacturing efficiency by producing entire assemblies in one operation while managing tooling complexity through functional integration.
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 manufacturing time, cost, and the need for fasteners by enabling the co-curing of composite components in a single step, minimizing rework and material waste, and eliminating the requirement for autoclave processing.
Implementation Method 1
generating heat using a heating system in the curing tool while one or more smart bladders are in a rigid state such that the heat has a thermal profile for curing the uncured composite structure
Implementation Method 2
one or more smart bladders that encompass the heating system... while one or more smart bladders are in a rigid state
Data Source
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AI summary
A method and apparatus for a composite structure manufacturing system (104). The system (104) comprises a heating system (106) and one or more smart bladders (144) that encompass the heating system (106). The heating system (106) and the one or more smart bladders (144) form a curing tool (128) defining a volume for the composite structure (102) when one or more smart bladders (144) of the one or more smart bladders (144) is in a rigid state.