Thermoplastic Composite Fusing with Insulation and Vacuum Bagging
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Solution Overview
Problem
Traditional methods for manufacturing composite parts, especially those with complex three-dimensional characteristics, require multiple disparate steps and costly components, leading to increased time and expense.
Innovation Solution
A system and method for manufacturing composite parts that involves laying a skin on a shaping surface of a tool, applying a substructure with a flange and raised segment, using insulation layers, and enclosing the composite part with a vacuum bag and the shaping surface, while applying heat to fuse the substructure to the skin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods are used to manufacture composite parts with complex three-dimensional characteristics, then the parts can be manufactured with required precision, but the process requires multiple disparate steps and costly components, resulting in increased time and expense
Solution Approach 1:
The patent combines skin laying and substructure fusing into a single integrated process. The skin is laid up on a shaping surface, and the substructure is subsequently fused directly onto the skin in the same tooling setup, eliminating the need for separate tooling and handling steps that would otherwise be required for complex three-dimensional parts
2Manufacturing precision
If traditional methods are used to manufacture composite parts, then the parts can be manufactured with required precision, but multiple disparate steps are required, leading to increased manufacturing time
Solution Approach 1:
The patent enables continuous manufacturing by maintaining the part in a single tooling setup throughout the process. The skin is laid up, then the substructure is fused onto it without removing the part from the tooling, creating an uninterrupted manufacturing sequence that reduces cycle time while preserving precision
Solution Approach 2:
The skin is laid up on the shaping surface in advance, preparing the base structure before the substructure fusing operation begins. This preliminary preparation allows the subsequent fusing step to proceed efficiently without requiring additional setup or tooling changes
3Manufacturing precision
If traditional methods are used to manufacture composite parts, then the parts can be manufactured with required precision, but costly components and multiple steps are required, resulting in increased expense
Solution Approach 1:
The patent merges skin laying and substructure fusing into one integrated process using the same tooling setup. This consolidation eliminates the need for multiple disparate tooling systems and handling fixtures, reducing equipment costs and manufacturing expenses while maintaining the precision required for complex three-dimensional parts
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 the need for complex and costly components and shortens the manufacturing process, achieving efficient fusion of composite structures with reduced expense and time.
Implementation Method 1
a heating element supplying heat to the shaping surface
Implementation Method 2
application of heat and fusing of the substructure to the skin
Implementation Method 3
a vacuum bag covering the composite part such that the composite part is enclosed by the combination of the vacuum bag and the shaping surface of the tool
Data Source
AI summary
A system for fusing thermoplastic composite structures includes a skin and a substructure on an inner surface of the skin. The system also includes a shaping surface of a tool, with the skin laid up on the shaping surface. The shaping surface is configured to maintain the shape of an outer mold line. The system further includes at least one insulation layer applied over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and a vacuum bag at least partly enclosing the skin and the substructure. Heat can be applied to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.