Wedge-and-Plug Tooling for 3D Preform Compression Control

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Solution Overview

Problem

Existing methods for manufacturing carbon/carbon (C/C) composites are limited to simple flat structures with low interlaminar properties, and there is a need for more complex 3D structures with improved mechanical properties for high-temperature aerospace applications.

Innovation Solution

A wedge-and-plug tooling system is used to shape and compress fibrous preforms before carbonization, employing a female forming tool, gripper plates, and a multi-component wedge-and-plug arrangement to apply tension and pressure forces, allowing for the formation of 3D C/C parts with enhanced interlaminar properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If traditional planar preform methods are used, then manufacturing simplicity is maintained, but structural complexity and mechanical properties are limited

Engineering Contradiction:

Improvepreform structure complexityVSAvoidinterlaminar properties

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent transitions from 2D planar preforms to 3D complex geometries by introducing multi-directional fiber arrangements and volumetric tooling. The female forming tool with cavities and the wedge-and-plug system enable creation of three-dimensional composite structures with enhanced interlaminar properties through out-of-plane fiber orientations.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The forming system is divided into multiple independent components: female forming tool with cavities, wedge mechanisms, and plug elements. This segmentation allows each component to be optimized independently for complex shape formation while maintaining manufacturing feasibility through modular assembly and disassembly.

Inventive Principle:

Principle #1Segmentation

2Strength

If compression force is applied during pre-carbonization, then density and mechanical strength are improved, but preform deformation and shape control become difficult

Engineering Contradiction:

Improvecomposite densityVSAvoidpreform shape control

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The female forming tool cavities are pre-configured with the exact desired geometry before preform placement. The gripper plates are positioned to establish precise boundaries, and the wedge-and-plug system is arranged to apply compression forces along predetermined paths, ensuring both density improvement and shape control are achieved simultaneously.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Compression forces are applied locally through wedge-and-plug mechanisms at specific regions rather than uniformly across the entire preform. The gripper plates constrain specific boundaries while allowing other regions to be compressed, enabling localized density enhancement without compromising overall shape control.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If simple 2D structures are manufactured, then manufacturing process simplicity is maintained, but application versatility for aerospace is limited

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidaerospace application suitability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The wedge-and-plug tooling system with female forming tools is designed to accommodate multiple preform geometries and composite configurations within the same basic framework. The modular cavities and adjustable compression mechanisms enable production of various 3D structures suitable for different aerospace applications, from brake discs to structural components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The system enables the production of 3D C/C parts with superior high-temperature characteristics and improved mechanical strength, suitable for high-temperature aerospace applications by maintaining pressure application during pre-carbonization compression.

Implementation Method 1

The gripper plate is configured to apply a tensioning force to the fibrous preform

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

The wedge is configured to engage the first plug and the second plug to move the first plug and the second plug laterally toward opposing sidewalls of the female forming tool to apply a pressure force to the fibrous preform

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS20260028286A1Wedge and plug tooling for pre-carbonization compression of oxidized pan fiber preform

Publication Date: 2026.01.29 GOODRICH CORP

AI summary

A shape forming tool for pre-carbonization compression of a fibrous preform is provided, comprising a female forming tool, a first plug, a second plug, and a wedge, each configured to be received by a die recess of the female forming tool. A first tapered surface of the wedge is configured to engage the first plug and the second tapered surface of the wedge is configured to engage the second plug. In response to the first tapered surface of the wedge engaging the first plug and the second tapered surface of the wedge engaging the second plug, the first plug and the second plug, respectively, are configured to move laterally towards opposing sides of the female forming tool and/or vertically toward a bottom side of the female forming tool to compress the fibrous preform into a shaped body.