Automated Vacuum Bag Dispensing for Composite Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The vacuum bagging process for composite parts, such as aircraft wings, faces challenges with inconsistencies and tolerancing issues due to the use of volatile chemicals and manual application of materials, leading to increased costs and potential scrapping of mission-critical parts.
Innovation Solution
The implementation of automated systems for dispensing and assembly of vacuum bagging materials, enhanced forming tools with integrated temperature measurement and adjustment capabilities, and 3D printing of forming tools to create customized geometries and integrate thermocouples and heating elements, along with automated carts for efficient autoclave operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If volatile chemicals are used to form release agents on the forming tool, then the composite part can be removed from the tool after curing, but expensive ventilation and safety equipment is required
Solution Approach 1:
The patent extracts and eliminates the volatile chemical release agents from the forming tool surface. Instead of applying chemical release agents, the tool surface is prepared with a non-stick coating or surface treatment that provides release capability without volatile chemicals, thereby removing the need for expensive ventilation and safety equipment while maintaining the ability to remove cured parts.
Solution Approach 2:
The patent employs disposable peel plies or release films that are applied to the tool surface. These single-use materials provide the necessary release function during curing and are discarded after part removal, eliminating the need for expensive reusable ventilation systems while ensuring consistent release performance.
2Adaptability or versatility
If vacuum bagging materials are manually applied to the composite part, then the process is flexible and adaptable, but air bubbles and inconsistencies form within the composite part
Solution Approach 1:
The patent replaces the manual mechanical application of vacuum bagging materials with an automated dispensing system. Computer-controlled dispensers precisely apply consumable materials such as release agents, sealants, and vacuum bag materials in predetermined patterns, eliminating manual variability and preventing air bubbles while maintaining adaptability through programmable control.
Solution Approach 2:
The patent implements self-aligning and self-adjusting vacuum bagging materials that automatically conform to the composite part geometry. The materials are designed with inherent properties that enable them to self-position and adapt to contours without manual intervention, ensuring consistent application and eliminating defects while maintaining flexibility.
3Manufacturing precision
If automated systems are implemented for dispensing vacuum bagging materials, then manufacturing precision and consistency improve, but device complexity increases
Solution Approach 1:
The patent designs multi-functional automated dispensing systems that can handle multiple types of consumable materials (release agents, sealants, vacuum bag materials) with a single integrated platform. The system can be programmed to perform different dispensing tasks, reducing the need for multiple separate devices and minimizing overall system complexity while maintaining high precision.
Solution Approach 2:
The patent employs computer-controlled parameters and programmable settings that allow the automated dispensing system to adapt to different part geometries and material requirements through software configuration rather than hardware changes. This flexibility reduces physical system complexity while maintaining manufacturing precision across various applications.
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 inconsistencies, minimizes the need for expensive ventilation equipment, and enhances the quality and cost-effectiveness of composite part fabrication by automating material application and temperature control during the curing process.
Implementation Method 1
a thermocouple integrated within the tool configured to sense temperature at a surface of the tool
Implementation Method 2
heating elements integrated within the tool configured to generate heat that conducts to a surface of the tool
Implementation Method 3
heating elements integrated within the tool configured to generate heat that conducts to a surface of the tool
Implementation Method 4
As air is drawn from the vacuum bag, the bag applies pressure to contour and consolidate the laminate against the forming tool. The vacuum bag also removes volatile compounds present within the laminate.
Data Source
AI summary
Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a selected location for placing the composite part on the tool, to direct the dispensers to apply a mold release agent onto the tool based on the selected location, to apply a sealant onto the tool proximate to the selected location, to lay up a ply of constituent material for the composite part atop the mold release agent at the selected location, to apply a pressure pad material atop the constituent material, to apply a breather material atop the pressure pad, and to apply vacuum bag material atop the ply proximate to the selected location to cover the ply as well as the sealant.