Vacuum Securement of Composite Parts to Complex Surfaces
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Solution Overview
Problem
The assembly of composite parts, such as Carbon Fiber Reinforced Polymer (CFRP) laminates, onto complex surfaces is challenging due to their inability to support themselves before hardening, leading to issues like peeling or shifting during layup, and the need for labor-intensive vacuum bag securing methods that require careful handling to avoid damaging the material.
Innovation Solution
A high-volume vacuum system that secures objects to complex surfaces using an impermeable membrane and negative pressure, eliminating the need for glue or fasteners and allowing for rapid placement and movement of large, unwieldy laminates without sealant application, by creating a vacuum seal that offsets air leaks and maintains the laminate in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional vacuum bag securing methods are used with tacky tape, then the laminate can be secured to the tool surface, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent removes the tacky tape intermediary from the securing process. Instead of using tape to attach the vacuum bag to the tool surface, the system directly secures the laminate to the tool surface through vacuum pressure applied through the bag, eliminating the labor-intensive tape application step while maintaining securing effectiveness
Solution Approach 2:
The vacuum bag itself becomes the intermediary that transfers vacuum pressure from the pump to the laminate and tool surface interface. By using the flexible membrane of the vacuum bag to distribute and transmit the vacuum force, the system achieves secure attachment without requiring separate fastening materials like tacky tape
2Reliability
If tacky tape is used to secure the vacuum bag, then the laminate can be held in place, but the tape is not contact approved and cannot touch the uncured composite material
Solution Approach 1:
The patent completely removes the tacky tape from the process, eliminating the contamination risk associated with non-contact-approved materials. The vacuum bag and pump system provide securing force without requiring any additional materials that could potentially contaminate the uncured composite
Solution Approach 2:
The vacuum system uses only contact-approved materials (the vacuum bag and pump) to provide securing force. The system serves itself by using the vacuum pressure directly through the bag to hold the laminate, without needing separate fastening materials that would require contamination checks
3Object-affected harmful factors
If the entire layup must be completed before applying the vacuum bag, then material contact approval requirements are met, but the process time increases
Solution Approach 1:
The vacuum bag is applied and secured to the tool surface before the laminate is fully laid up. The preliminary vacuum application creates a secure foundation that prevents the laminate from shifting or peeling during the remaining layup operations, eliminating the need to wait until completion before applying the bag
Solution Approach 2:
The system allows for dynamic, staged application of the vacuum bag during the layup process. The vacuum can be applied incrementally as sections of the laminate are placed, allowing the process to proceed in stages rather than requiring complete layup before vacuum application
4Shape
If large laminates are laid up onto complex surfaces, then the desired shape is achieved, but the laminates may peel off or shift before hardening
Solution Approach 1:
The vacuum bag, as a flexible membrane, conforms to complex tool surface geometries while maintaining uniform vacuum pressure distribution. This flexible shell adapts to barrel shapes and other complex surfaces, providing stable positioning force across the entire laminate surface without rigid structural constraints
Solution Approach 2:
The vacuum system creates uniform pressure distribution across the entire laminate surface through the flexible bag. This equipotential pressure field ensures consistent securing force throughout the laminate, preventing localized peeling or shifting that could occur with non-uniform pressure distribution
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 enables quick and effective securement of large composite parts to complex surfaces, reducing the risk of drooping or peeling and minimizing labor, while maintaining the structural integrity and cleanliness of the parts by avoiding sealant application, thus enhancing the efficiency and reliability of composite part assembly processes.
Implementation Method 1
applying a negative pressure to the vacuum port that offsets air leaks between the impermeable membrane and the object
Implementation Method 2
applying a negative pressure to the vacuum port that evacuates air between the impermeable membrane and the object, the negative pressure directly securing the impermeable membrane by evacuation of air between the object and the impermeable membrane
Data Source
AI summary
Systems and methods are provided for vacuum handling of composite parts. One embodiment is a method for performing vacuum securement of an object. The method includes covering the object with an impermeable membrane, locating a vacuum port at the impermeable membrane, and applying a negative pressure to the vacuum port that offsets air leaks between the impermeable membrane and the object.