Reusable Vacuum Compaction Device for Composite Layups
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Solution Overview
Problem
The existing methods for compacting composite materials are time-consuming, labor-intensive, and material-intensive, requiring custom-fitting polymeric sheets and manual taping, which is inefficient and prone to contamination.
Innovation Solution
A reusable vacuum compaction device with a barrier structure and sealing mechanism that forms a fluid seal on a supporting surface, applying a vacuum to compact the composite material without the need for extensive sheeting and taping, allowing for efficient compaction on various surface geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymeric sheet and tape method is used for compaction, then the charge of composite material can be compacted, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent extracts and eliminates the time-consuming steps of custom-fitting polymeric sheets and manual taping by using a reusable vacuum compaction device with integrated sealing structures. The device directly applies vacuum pressure without requiring these intermediate materials, thereby removing the problematic elements from the process while maintaining compaction effectiveness.
Solution Approach 2:
The vacuum compaction device is designed to be self-contained with integrated sealing structures that automatically form seals against the layup mandrel surface. This self-service design eliminates the need for manual intervention in fitting and taping operations, allowing the device to perform compaction independently and efficiently.
2Reliability
If polymeric sheets and tape are used for compaction, then the charge can be compacted, but material consumption increases
Solution Approach 1:
The patent implements a reusable vacuum compaction device that can be recovered and reused for multiple compaction operations. Unlike single-use polymeric sheets and tapes that are discarded after one use, this device maintains its functionality across multiple cycles, significantly reducing material consumption and waste.
Solution Approach 2:
The vacuum compaction device is designed with universal applicability to work with various layup mandrel geometries and composite material configurations. This multi-functionality allows a single device to replace multiple custom-fitted polymeric sheets, reducing overall material consumption while maintaining compaction effectiveness across different applications.
3Reliability
If oversized polymer sheets are used for interior surface compaction, then the charge can be compacted, but the process requires additional materials and time
Solution Approach 1:
The vacuum compaction device incorporates flexible sealing structures that can dynamically adapt to different layup mandrel geometries, including interior surfaces. This dynamic adaptability eliminates the need for oversized, rigid polymeric sheets, simplifying the compaction setup while maintaining effective sealing and compaction across various surface configurations.
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 significantly reduces the time and material required for compaction, prevents contamination, and allows for repeated use of the device without damage, enhancing the efficiency and versatility of composite material processing.
Implementation Method 1
a vacuum distribution manifold that is in fluid communication with and configured to selectively apply a vacuum to the enclosed volume. Application of the vacuum to the enclosed volume may decrease a pressure within the enclosed volume and transition the vacuum compaction device from an undeformed configuration to a deformed configuration, thereby compacting the charge of composite material
Implementation Method 2
a sealing structure that is configured to form a fluid seal when compressed between the supporting surface and the barrier structure
Data Source
AI summary
Systems and methods for compacting a charge of composite material. These systems and methods may utilize a vacuum compaction device to compact the charge of composite material on a supporting surface. The vacuum compaction device may be reusable and may be configured to define an enclosed volume when positioned on the supporting surface and may include a barrier structure and a sealing structure that is configured to form a fluid seal when compressed between the supporting surface and the barrier structure. The vacuum compaction device also may include a vacuum distribution manifold that is in fluid communication with and configured to selectively apply a vacuum to the enclosed volume. Application of the vacuum to the enclosed volume may decrease a pressure within the enclosed volume and transition the vacuum compaction device from an undeformed configuration to a deformed configuration, thereby compacting the charge of composite material on the supporting surface.