Composite Wing Cover Shaping with Magnetic Retention
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Solution Overview
Problem
Current methods for manufacturing composite wing covers are complex and time-consuming, requiring extensive preparation and autoclave curing, which prolongs the lead time.
Innovation Solution
A method and device that uses shaping tools with magnetic retention and longitudinal heating elements, along with a vacuum bag, to simplify the process by shaping, attaching, and curing laminates and skin within these tools, eliminating the need for an autoclave.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If female tools with semirigid inflatable mandrels are used for shaping and co-curing, then the stringers and skin can be formed to desired shape, but the process becomes complex and requires extended lead time
Solution Approach 1:
The manufacturing process is divided into separate stages: shaping stringers in shaping tools, then co-curing with skin in autoclave. This segmentation allows each tool to be optimized for its specific function, reducing overall process complexity while maintaining shape quality.
Solution Approach 2:
Semirigid inflatable mandrels are introduced as intermediary elements inside the female tools to support and define the stringer shape during lamination. These mandrels can be inflated to the desired shape and then deflated for removal, simplifying the tooling design while ensuring accurate stringer geometry.
2Shape
If female tools with semirigid inflatable mandrels are used for shaping and co-curing, then the stringers and skin can be formed to desired shape, but the lead time is extended
Solution Approach 1:
Stringers are pre-shaped in the shaping tools with mandrels before the co-curing operation. This preliminary shaping action allows the stringers to be prepared in advance and positioned on the skin, enabling parallel processing and reducing the overall lead time compared to forming everything in one step.
3Reliability
If autoclave is used for co-curing, then the skin and stringers can be cured, but energy consumption is high
Solution Approach 1:
The curing process is separated from the shaping process. Stringers are shaped at room temperature or low temperature, then only the skin and stringer assembly requires autoclave curing. This segmentation reduces the volume and time requiring high-energy autoclave operation, lowering overall energy consumption while maintaining curing quality.
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 significantly reduces preparation time and energy consumption by allowing in-tool shaping, retention, and curing of composite wing covers, enabling faster production and lower energy use.
Implementation Method 1
retaining the shaped laminates inside the shaping tools; Advantageously, the shaped laminates are retained inside the shaping tools by magnetism
Implementation Method 2
curing the shaped laminates by heating the shaping tool; the heating of the shaping tools is done by heating longitudinally the internal surface of the shaping tools
Implementation Method 3
in the curing step, the vacuum is preferably created in the shaping tools closing a vacuum bag around the shaping tools
Data Source
Figure 1
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Figure 4~5
AI summary
The method comprises: placing a laminate (1) inside each of a plurality of shaping tools (2); shaping the laminates (1) pressing the laminates (1) against the shaping tools (2); retaining the shaped laminates (1) inside the shaping tools (2); turning over the shaped laminates (1); attaching a skin (8) to the shaped laminates (1); and curing the skin (8) and the shaped laminates (1), heating the shaping tools (2) and creating a vacuum in the shaping tools (2). The device comprises a plurality of shaping tools (2) for placing a laminate (1) inside each of them; deforming tools (5) for pressing the laminates (1) against the shaping tools (2) for shaping the laminates (1); magnetic means (4, 7) for retaining the shaped laminates (1) inside the shaping tools (2); and the shaping tools (2) comprise heating elements (9) for curing the shaped laminates (1).