Stiffened Composite Panel Manufacturing via Single Laminate Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing stiffened composite panels in the aeronautical industry require multiple laminates and processes, leading to high costs, long lead times, and debonding risks due to the use of rivets and multiple curing cycles, while also struggling to achieve efficient stiffness and weight ratios.
Innovation Solution
A method involving the creation of a single flat laminate with pre-preg elongated reinforcing elements, strategically cut to enhance deformability, which is then formed and integrated with the skin in a single curing process, eliminating the need for multiple laminates and reducing the number of curing cycles and labor hours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple laminates are used to manufacture longitudinal reinforcing elements, then the structural integrity is improved, but the recurring costs and lead time increase
Solution Approach 1:
The patent combines multiple separate laminates into a single monolithic laminate that integrates both the skin and longitudinal reinforcing elements (stringers) into one continuous structure. This merging eliminates the need for separate laminates while maintaining structural integrity through continuous fiber reinforcement throughout the entire panel.
Solution Approach 2:
The single laminate serves multiple functions simultaneously: it provides the skin structure, contains embedded stringers for reinforcement, and eliminates the need for separate assembly operations. The laminate acts as both the base structure and the reinforcement carrier, reducing overall manufacturing steps.
2Manufacturing precision
If multiple curing cycles are applied, then the quality of each component is improved, but the production time and costs increase
Solution Approach 1:
The patent merges multiple curing operations into a single curing cycle that cures the entire monolithic panel structure in one continuous process. This eliminates sequential curing steps while maintaining quality through controlled curing parameters applied to the integrated structure.
3Strength
If rivets are used to join stringers and skin, then the structural connection is improved, but the weight and debonding risks increase
Solution Approach 1:
The patent merges the skin and stringers into a single integrated laminate structure where the stringers are embedded within the skin material. This eliminates the need for separate joining mechanisms like rivets, as the structure is continuously bonded throughout, reducing weight while maintaining connection strength.
4Strength
If traditional co-curing processes are used, then the integration of stringers and skin is improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent combines the skin and stringers into a single pre-designed monolithic laminate that requires only one curing cycle and one assembly operation. This merging simplifies the manufacturing process by eliminating multiple positioning, assembly, and curing steps while maintaining strong integration between components.
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 recurring costs and lead times, improves the quality and reproducibility of the panel shape, and eliminates the need for riveting, resulting in a more efficient and cost-effective manufacturing process with enhanced stiffness and weight ratios.
Implementation Method 1
laying up a flat laminate comprising stacked plies of composite layers for forming a structure comprising the elongated reinforcing elements of the panel
Implementation Method 2
integrating together by curing the skin and the formed structure comprising the elongated reinforcing elements
Data Source
AI summary
A method for manufacturing a stiffened panel made from composite material comprising a skin and elongated reinforcing elements wherein some of the elongated reinforcing elements cross each other. The method comprises the steps of (a) laying up a flat laminate comprising stacked plies of composite layers for forming a structure comprising the elongated reinforcing elements of the panel, (b) cutting the flat laminate along intersection lines of planes defining the webs of two crossing reinforcing elements, (c) cutting in the flat laminate the outline of the elongated reinforcing elements, (d) forming the structure comprising the elongated reinforcing elements of the panel, (e) laying up plies of composite layers for forming the skin, and (f) curing the laid-up plies of the skin and the formed structure comprising the elongated reinforcing elements.