Automated Solid Laminate Stringer Fabrication on Composite Panels

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for fabricating solid laminate stringers in the aerospace industry are labor-intensive and require manual or semi-manual placement and splicing of composite layers, leading to flaws, wrinkling, and difficulties in accommodating curved surfaces and high-volume production demands.

Innovation Solution

The method involves unspooling, compacting, cutting, and curing continuous composite layers on a composite panel using automated digital model controlled processes, eliminating manual placement and splicing, and allowing for widths, lengths, and curvatures without splicing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual or semi-manual placement of composite layers is used, then flexibility in placement is maintained, but labor intensity increases and production rate decreases

Engineering Contradiction:

Improveflexibility in placementVSAvoidproduction rate

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces manual or semi-manual mechanical placement operations with an automated fiber placement system that uses robotic end-effectors to deposit composite layers. This substitution eliminates manual labor while maintaining placement flexibility through programmable motion control, thereby resolving the contradiction between ease of operation and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements automated control systems that can dynamically adjust placement parameters such as fiber orientation angles, layer thicknesses, and deposition speeds based on pre-programmed trajectories. This parameter automation allows the system to adapt to complex geometries while maintaining high production rates, addressing both flexibility and productivity requirements.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If manual or semi-manual placement and splicing is used, then accommodation of curved surfaces is achieved, but flaws and wrinkling are generated

Engineering Contradiction:

Improveaccommodation of curved surfacesVSAvoidsurface quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent replaces manual splicing operations with automated fiber placement that continuously deposits composite material without interruption. The automated system follows precise pre-programmed paths that conform to curved surfaces, eliminating the need for splicing and thereby preventing the generation of flaws and wrinkling while maintaining adaptability to complex geometries.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs pre-programmed motion trajectories and digital models that are prepared in advance to match the specific curvature and geometry of the workpiece. This preliminary digital preparation allows the automated system to anticipate and adjust fiber placement paths before actual deposition, ensuring flawless surface quality on curved surfaces without manual intervention.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If manual or semi-manual placement is used, then adaptability to different configurations is maintained, but labor requirements increase

Engineering Contradiction:

Improveadaptability to different configurationsVSAvoidlabor requirements

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements a programmable automated fiber placement system where different composite layer configurations are achieved by changing software parameters such as fiber orientation angles, layer stacking sequences, and deposition patterns. This parameter-based adaptability eliminates the need for manual reconfiguration for each design variant, thereby reducing labor requirements while maintaining versatility.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent develops a universal automated fiber placement system that can handle multiple composite layer configurations, curvatures, and geometries through a single multi-functional platform. The system's programmable nature allows it to perform various placement tasks without requiring separate manual operations for each configuration, thereby reducing overall labor requirements while maintaining broad adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Length of moving object

If splicing composite layers is used, then length accommodation is achieved, but additional labor and potential defects are introduced

Engineering Contradiction:

Improvelength accommodationVSAvoidproduction efficiency

Core Design Contradiction:

Length of moving objectVSProductivity

Solution Approach 1:

The patent implements continuous automated fiber placement that deposits composite layers without interruption or splicing. The automated system maintains continuous material supply and deposition operations, eliminating the need for splicing to accommodate lengths. This continuity not only simplifies the process but also improves production efficiency by removing the time and labor associated with splicing operations.

Inventive Principle:

Principle #20Continuity of useful action

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 labor requirements, minimizes defects and wrinkling, and enables high-volume, high-rate production of solid laminate stringers with improved quality and safety, while also reducing material and space needs.

Implementation Method 1

The curing the one or more composite layers unspooled onto the composite panel may include placing a vacuum bag over the one or more composite layers and applying a compaction pressure to the one or more composite layers

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

The unspooling one or more composite layers onto the composite panel may include using overhead laser projection to synchronize the unspooling one or more composite layers according to at least one of a move speed, a rotation rate, a compacting pressure, and a heating temperature

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 3

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS12220890B2Methods for fabricating solid laminate stringers on a composite panel

Publication Date: 2025.02.11 THE BOEING CO

AI summary

A method of fabricating a solid laminate stringer on a composite panel, including unspooling one or more composite layers onto the composite panel; compacting the one or more composite layers unspooled onto the composite panel; cutting the one or more composite layers unspooled onto the composite panel; and curing the one or more composite layers unspooled onto the composite panel, wherein the one or more composite layers are unspooled continuously along a length corresponding to a length of the solid laminate stringer.