Unitized Composite Wave-Flat Bonding Process
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Solution Overview
Problem
Existing methods for creating composite structures with sinuous and flat elements require separate production and lamination of roll goods, leading to inefficiencies, increased complexity, and higher costs due to the need for multiple roll good layers and specialized equipment.
Innovation Solution
A process involving the deposition of contractive and non-contractive layers, shaped into a sinuous form, and activated to bond the contractive elements into a flat surface while maintaining the non-contractive elements in a sinuous state, eliminating the need for pre-made roll goods and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate roll goods are produced and laminated to create composite structures with sinuous and flat elements, then the structural properties (stiffness, load-bearing capability) are achieved, but the manufacturing complexity and equipment requirements increase significantly
Solution Approach 1:
The patent combines the production of sinuous and flat elements into a single integrated process. Multiple layers are deposited simultaneously on a moving substrate, with contractive layers forming sinuous elements and non-contractive layers forming flat elements, eliminating the need for separate production and lamination equipment
Solution Approach 2:
The moving substrate serves multiple functions: it supports layer deposition, provides the flat element structure, and enables the formation of sinuous elements through differential contraction during drying. This multi-functional approach replaces multiple specialized machines with a single versatile system
2Strength
If multiple roll good layers are used to create composite structures, then the desired structural properties are achieved, but material costs and waste increase
Solution Approach 1:
The composite structure is segmented into contractive layers (forming sinuous elements) and non-contractive layers (forming flat elements) that are deposited in controlled sequences. This segmentation allows precise material placement and reduces waste by using only the necessary amount of each material type
Solution Approach 2:
The patent controls material properties through parameter changes during deposition and drying. By adjusting contraction parameters during the drying process, the system transforms flat deposited layers into sinuous elements in-place, eliminating material waste associated with pre-formed corrugated materials
3Ease of manufacture
If pre-made roll goods are laminated together, then the manufacturing process is established, but the process complexity and time requirements increase
Solution Approach 1:
The patent implements continuous layer deposition on a moving substrate, where multiple layers are deposited and bonded in a single continuous operation. This eliminates the intermittent handling, alignment, and lamination steps required when working with separate roll goods, significantly reducing manufacturing time
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 simplifies the manufacturing process, reduces material costs, and achieves desirable structural properties like stiffness and load-bearing capabilities while minimizing waste and complexity.
Implementation Method 1
at least one of which is capable of substantial contraction relative to the other elements upon activation
Data Source
AI summary
A simplified manufacturing technique to directly form a unitized composite structure with at least one relatively flat surface and at least one sinuous element in an internally-bonded unitized composite is provided. A matrix of fibrous and or other materials is deposited in layers which are subsequently formed into corrugated or wave-like shapes and exposed to an activation step. At least one element is composed of a contractive material which shrinks when activated, such as by heating in an oven, to become relatively flat and optionally bonded to at least one other non-contractive layer which remains in a sinuous shape after the activation step.