Thermoplastic Fiber Placement System Spatial Segmentation
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Solution Overview
Problem
The manufacturing of fiber-reinforced composite structures is time-consuming and expensive due to the need for high-engineered tools and the autoclave-based curing process, which increases costs and reduces production efficiency.
Innovation Solution
A fiber placement system and method that utilize thermoplastic composite materials, allowing for the construction of reinforcement layups at separate locations and consolidating them at a distinct location, reducing the need for high-engineered tools and enabling increased production rates and cost savings by leveraging room temperature handleability of thermoplastic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If autoclave-based curing process is used, then composite structure is cured or consolidated, but manufacturing time increases and production rate decreases
Solution Approach 1:
The patent divides the manufacturing process into separate stages: layup construction at a first location and consolidation at a second location. This segmentation allows the time-consuming autoclave curing to be performed on pre-assembled layups rather than large complex structures, significantly reducing overall manufacturing time while maintaining curing quality.
Solution Approach 2:
The patent performs preliminary layup construction and assembly at a first location before transporting to the second location for consolidation. This preliminary action allows preparation work to be completed in advance, enabling faster final assembly and reducing the time the expensive autoclave equipment is occupied.
2Reliability
If highly engineered tools are used for autoclave process, then consolidation is achieved, but manufacturing costs increase
Solution Approach 1:
By segmenting the process into layup construction and consolidation stages at different locations, the patent reduces the complexity requirements for each individual tool. The first location tools only need to handle layup assembly, while the second location tool handles consolidation, allowing use of simpler, less expensive equipment compared to a single highly engineered autoclave system.
Solution Approach 2:
The patent extracts the consolidation function from the layup construction process, separating it into a distinct second location. This extraction allows each location to use specialized, simplified tools optimized for its specific function rather than requiring one highly engineered tool to perform all functions, thereby reducing overall manufacturing costs.
3Device complexity
If layup and consolidation are performed at the same location, then process integration is achieved, but production efficiency decreases
Solution Approach 1:
The patent spatially segments the manufacturing process into two distinct locations: first location for layup construction and second location for consolidation. This geographic segmentation allows parallel processing and specialization of equipment at each location, improving overall manufacturing efficiency despite the apparent increase in process complexity.
Solution Approach 2:
The patent transitions from a single-location vertical integration model to a multi-location horizontal distribution model. By distributing different process stages across different geographic locations, the system achieves better resource utilization and production efficiency, allowing simultaneous operation of multiple production lines.
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 increases manufacturing production rates while decreasing costs by allowing for the use of simpler tools and spatially separating layup and consolidation processes, thereby enhancing efficiency and reducing expenses.
Implementation Method 1
a heating unit positioned to supply heat proximate the nip
Implementation Method 2
the fiber tow is generally pressed onto the underlying layup at a compaction nip using a compaction roller
Implementation Method 3
the reinforcement layup and the associated tool are placed into an autoclave and heated to a predetermined temperature for a predetermined amount of time
Data Source
AI summary
A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.