Symmetric Composite Parts Single Tool Curing
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Solution Overview
Problem
The existing methods for manufacturing carbon fiber reinforced composite parts for aircraft require separate tooling and fabrication processes for symmetric left and right hand portions, leading to increased costs, time, and material waste due to the need for trimming and cutting of cured parts for attachment fittings.
Innovation Solution
A method where multiple sheets of fibrous material are positioned on a single tool surface, infused with resin, cured as a single structure, and then divided along a plane to produce symmetric composite parts, eliminating the need for separate tooling and reducing material waste by creating attachment cavities without additional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate tooling is used for manufacturing symmetric left and right hand composite parts, then manufacturing precision and part quality are maintained, but tooling costs and device complexity double
Solution Approach 1:
The patent merges the manufacturing of symmetric left and right hand composite parts into a single integrated process. Multiple tool surfaces are combined on one tooling assembly, allowing simultaneous production of both symmetric parts from a single mold structure, thereby halving the tooling investment while maintaining quality standards through controlled curing parameters.
Solution Approach 2:
The tooling assembly is designed with multiple tool surfaces that can manufacture different symmetric parts on the same aircraft side or opposite sides. This multi-functional tooling structure allows a single tool to produce multiple part types (e.g., left wing, right wing, or other symmetric components), increasing tooling versatility and reducing the need for dedicated tooling for each part.
2Manufacturing precision
If separate fabrication processes are used for symmetric parts, then manufacturing precision is maintained, but fabrication time and productivity are reduced
Solution Approach 1:
The patent enables continuous fabrication by curing multiple composite parts simultaneously in a single autoclave cycle. While one set of parts cures, the tooling can be prepared for the next batch, eliminating idle time between curing cycles. This continuous production flow maintains quality through consistent curing parameters while significantly increasing overall manufacturing throughput.
Solution Approach 2:
Multiple composite parts are laid up and positioned on the tool surfaces in advance before the curing cycle begins. This preliminary preparation allows all parts to be ready for simultaneous curing, eliminating sequential processing delays and enabling parallel production without compromising the quality that would result from controlled, standardized curing procedures.
3Ease of operation
If trimming and cutting are performed on cured composite parts, then attachment fitting requirements are met, but material waste and loss of substance increase
Solution Approach 1:
The tool surfaces are designed with integrated cavities that match the desired final shape of the composite parts, including the attachment fitting configurations. During the molding process, the composite material is formed directly into the final geometry with cavities ready for fittings, eliminating the need for post-curing trimming and cutting operations that would waste valuable composite material.
Solution Approach 2:
The patent changes the geometric parameters of the tool surfaces to include the attachment fitting cavities as integral features. By incorporating the fitting cavity geometry into the tooling design itself, the final part emerges with the correct shape and attachment features already formed, avoiding material removal operations and associated waste.
4Adaptability or versatility
If separate tooling is used for symmetric parts, then manufacturing flexibility is maintained, but factory space and area requirements double
Solution Approach 1:
The patent combines multiple tool surfaces into a single integrated tooling assembly that can produce multiple symmetric parts simultaneously. This consolidation reduces the physical footprint required in the factory, as one tool occupies the space that would otherwise be needed for multiple separate tools, while maintaining the flexibility to produce various part configurations.
Solution Approach 2:
The multi-functional tooling assembly can produce different symmetric parts by reconfiguring or selecting different tool surfaces, reducing the need for multiple dedicated tooling sets. This universal tooling approach maintains manufacturing flexibility while minimizing the factory floor space required for tooling storage and operation.
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 significantly reduces tooling costs, fabrication time, and factory space while minimizing material waste by manufacturing symmetric composite parts in a single process, enabling efficient assembly of aircraft components.
Implementation Method 1
The resin permeates the plurality of sheets.
Implementation Method 2
The plurality of sheets and the resin infused into the plurality of sheets are then cured on the tool surface.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In a method of producing symmetrical carbon fiber reinforced composite parts (94, 96), a plurality of sheets of fibrous material (32) configured as a single structure are positioned on a tool surface (34) where the single structure is comprised of a first composite part (94) joined to a symmetric, second composite part (96). The single structure (92) is infused with resin and cured on the tool surface (34), producing a single cured structure (92) comprised of a first cured composite part (94) joined to a second cured composite part (96). The single cured structure (92) is then divided along a dividing plane, producing the symmetric first cured composite part (94) and second cured composite part (96).