Tailored-Stiffness Composite Filler Members for Gap Matching
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Solution Overview
Problem
Existing composite filler members lack the ability to tailor stiffness to meet structural requirements, leading to undesirable manufacturing costs and times, and often fail to match the geometric shapes of gaps or voids in composite structures.
Innovation Solution
A method involving cutting elongated fibers within a composite blank to form discrete sections, arranging them in a corrugated configuration, and shaping the composite blank to achieve a desired stiffness and match the shape of gaps, using a roll cutting die and forming machines to create a composite filler member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional composite filler members are used, then manufacturing cost and time are reduced, but stiffness cannot be tailored to meet structural requirements
Solution Approach 1:
The composite filler member is divided into multiple discrete fiber sections along its length, with varying numbers of cuts per section. This segmentation allows different regions to have different stiffness characteristics, enabling tailored performance while maintaining efficient manufacturing processes.
Solution Approach 2:
Different sections of the composite filler member have different fiber cut densities and configurations, creating local variations in stiffness. Areas requiring higher stiffness have more fiber sections, while areas requiring flexibility have fewer sections, optimizing both performance and manufacturing efficiency.
2Device complexity
If existing composite filler members are used, then manufacturing process is simple, but structural performance does not meet requirements
Solution Approach 1:
The fiber cutting pattern is predetermined and programmed into the manufacturing process, allowing complex stiffness distributions to be achieved through systematic pre-planning of cut locations and densities, maintaining process simplicity while enhancing structural performance.
Solution Approach 2:
The manufacturing process controls variables such as fiber cut density, cut location, and fiber section length to create tailored stiffness profiles. By adjusting these parameters during manufacturing, the process achieves enhanced structural performance without significantly increasing process complexity.
3Ease of manufacture
If uniform fiber configuration is used in composite filler member, then manufacturing is easier, but stiffness cannot be tailored for specific applications
Solution Approach 1:
The composite filler member is divided into multiple discrete fiber sections along its length, with varying numbers of cuts per section. This segmentation allows different regions to have different stiffness characteristics, enabling tailored performance while maintaining efficient manufacturing processes.
Solution Approach 2:
The fiber configuration transitions from uniform to varied along the length of the member, with cut densities changing to match structural requirements. This dynamic variation in fiber configuration enables the member to adapt to different structural needs while being manufactured through a systematic process.
Data Source
AI summary
A method of making a composite filler member with a tailored stiffness from a composite blank. The method includes cutting the elongated fibers within the composite blank and forming a plurality of shorter discrete fiber sections and forming the composite blank into a corrugated configuration. A composite filler material includes cut fiber sections and uncut fibers. A method of making a composite blank includes positioning the composite blank on a support surface and cutting one or more of the elongated fibers within the composite blank and reducing the initial stiffness of the composite blank to a working stiffness.