Vacuum Bag Securing for Composite Fuselage Parts
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Solution Overview
Problem
The manual mounting and securing of vacuum bags during the compacting phase of composite material fuselage components are labor-intensive, costly, and result in inconsistent quality and bag destruction, limiting the efficiency and reliability of the process.
Innovation Solution
An automated system using numeric-controlled machines and reusable compacting tools with semi-closed cell foam and vacuum bags, which are attached to a frame to create a sealed environment, allowing for precise vacuum application without manual intervention and enabling the reuse of vacuum bags.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual mounting and securing of vacuum bags is used, then the process can be performed with simple equipment, but labor intensity and costs increase significantly
Solution Approach 1:
The vacuum bag securing system uses vacuum pressure itself to perform the securing function. The vacuum bag is drawn into the securing groove and held in place by the vacuum pressure differential, eliminating the need for manual sealing operations. The system serves itself by using the process medium (vacuum) to perform the securing action.
Solution Approach 2:
The patent replaces manual mechanical operations (mounting and securing by hand) with a vacuum-based system. The vacuum pressure field substitutes for human hands and tools, automatically drawing the vacuum bag into position and securing it through pressure differential rather than mechanical fastening.
2Device complexity
If manual mounting and securing of vacuum bags is used, then equipment complexity remains low, but quality consistency deteriorates
Solution Approach 1:
The vacuum bag securing mechanism uses the vacuum pressure field to automatically position and secure the bag in a consistent manner. The vacuum pressure differential ensures the bag is drawn into the securing groove to the same position each time, eliminating variability introduced by different operators' skill levels.
Solution Approach 2:
The patent controls the vacuum pressure parameter to ensure consistent securing of the vacuum bag. By maintaining a specific vacuum pressure level, the system ensures that the bag is secured with consistent force and position across all operations, improving quality consistency.
3Reliability
If vacuum bags are glued to the compacting zone, then secure attachment is achieved, but the bags must be destroyed after use
Solution Approach 1:
The patent separates the attachment function from the vacuum bag material itself. The vacuum bag attaches to a reusable securing structure (groove and clamp system) rather than being permanently fixed to the compacting zone. This segmentation allows the bag to be released and reused while maintaining secure attachment during use.
Solution Approach 2:
The system enables recovery and reuse of the vacuum bags. Instead of destroying the bags after single use, the design allows them to be detached from the securing groove, inspected, and reused in subsequent compacting operations, reducing material waste.
4Productivity
If automated numeric-controlled machines are used, then manual labor is eliminated, but device complexity increases
Solution Approach 1:
The vacuum bag mounting and securing system uses the vacuum pressure field to perform the securing action automatically. The vacuum pressure differential causes the bag to be drawn into the securing groove and held in place without requiring additional actuators, sensors, or control systems beyond the vacuum pump itself.
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 method ensures consistent quality and reduces costs by eliminating manual labor, improving vacuum pressure consistency, and allowing for the reuse of vacuum bags, thereby enhancing the efficiency and reliability of composite material part manufacturing.
Implementation Method 1
compact the stringers by placing a vacuum bag (35) over the stringers and inside the frame (31)
Implementation Method 2
a layer of semi-closed cell foam material (33), having a first face connected to the entire perimeter of the lower side (32b) of the frame (31) and having a second face configured to come into contact with the compacting zone
Data Source
Figure 1
Figure 2~3b
Figure 3a
AI summary
The present invention relates to a system to manufacture composite material parts comprising a supporting mandrel having at least one compacting zone (12) configured to contain at least one composite material element (21) to be compacted by applying a certain degree of vacuum. The system comprises also at least one compacting equipment (30) comprising a frame (31) having a plurality of interconnected arms along a predetermined perimeter, at least one vacuum bag (35) attached to a side of the frame (31) along its perimeter and configured to compact the element (21), at least one porous material (33) attached to the vacuum bag (25) along the frame's perimeter and configured to adhere in a removable way to the compacting zone (12) and to impede the air influx during the compacting of element (21). The invention also relates to a compacting equipment and to a method to manufacture composite material parts.