Aeronautical Engine Thermoplastic Skin Lay-Up for Crystallinity Control
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Solution Overview
Problem
Current methods for manufacturing thermoplastic skins for aeronautical engines are energy-intensive due to the need for additional thermal cycles in autoclaves, leading to high costs and fragmented manufacturing processes, and lack control over the thermal cycle for achieving desired crystallinity.
Innovation Solution
A method involving a lay-up tooling with a thermal regulation device that locally heats and cools the thermoplastic material during deposition, using a depositing tool to control the thermal gradient and crystallinity, eliminating the need for separate autoclave cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional thermal cycles in autoclave are used to control crystallinity, then desired crystallinity level is achieved, but energy consumption increases
Solution Approach 1:
The patent combines the thermal cycle control function into the depositing tool itself, merging the deposition process and thermal treatment into a single integrated operation. The depositing tool includes heating means to provide thermal cycles during deposition and a cooling means integrated into the tool, eliminating the need for separate autoclave processing while maintaining crystallinity control.
Solution Approach 2:
The patent extracts the thermal regulation function from the separate autoclave process and incorporates it directly into the depositing tool. By integrating heating and cooling means within the depositing tool, the thermal cycle control is performed in-situ during deposition, removing the need for additional energy-intensive autoclave cycles.
2Manufacturing precision
If additional thermal cycles in autoclave are used to control crystallinity, then desired crystallinity level is achieved, but manufacturing process becomes fragmented
Solution Approach 1:
The patent merges multiple process steps (deposition and thermal cycle control) into a single integrated operation performed by the depositing tool. The tool simultaneously performs material deposition and applies thermal cycles with integrated heating and cooling means, creating a unified manufacturing process rather than fragmented sequential steps.
3Manufacturing precision
If additional thermal cycles in autoclave are used to control crystallinity, then desired crystallinity level is achieved, but manufacturing cycle time increases
Solution Approach 1:
The patent maintains continuous useful action by performing thermal cycle control during the deposition process itself, rather than pausing for separate autoclave cycles. The depositing tool continuously deposits material while simultaneously applying thermal cycles and cooling, eliminating idle time and reducing total manufacturing cycle time.
Solution Approach 2:
The patent performs preliminary thermal treatment during the deposition process itself, preparing the material with the required crystallinity structure before the part is complete. By applying thermal cycles and cooling during deposition rather than after, the process eliminates subsequent heat treatment steps and reduces total manufacturing time.
4Manufacturing precision
If additional thermal cycles in autoclave are used to control crystallinity, then desired crystallinity level is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines deposition and thermal treatment functions into a single depositing tool, eliminating the need for separate autoclave equipment and operations. This integration reduces capital equipment costs, operational expenses, and manufacturing complexity, making the process more economical while maintaining crystallinity control.
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 energy consumption, lowers manufacturing costs, and enhances the manufacturing speed by controlling crystallinity and adhesion properties of the thermoplastic material without additional thermal cycles.
Implementation Method 1
the depositing tool is configured to exert a pressure on the thermoplastic material and to heat the latter while it is being laid
Implementation Method 2
the lay-up tooling comprises a thermal regulation device configured to locally heat the surface of the lay-up tooling
Implementation Method 3
Semi-crystalline materials have the advantages of being resistant to chemical agents, fire, and abrasion. They also have better mechanical properties.
Implementation Method 4
the depositing tool is configured to exert a pressure on the thermoplastic material
Data Source
AI summary
Method for the manufacture of at least one skin, in particular of an acoustic panel for an aeronautical engine, including the laying of a thermoplastic material on a surface of a lay-up tooling, via a depositing tool configured to exert a pressure on the thermoplastic material and to heat the latter while it is being laid, wherein the lay-up tooling includes a thermal regulation device configured to locally heat the surface of the lay-up tooling.