Composite Layup Tool Segmentation for Laminate Extraction
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Solution Overview
Problem
The transfer process between layup tools and curing tools in composite part manufacturing is complicated due to tight radii of curvature and complex contours, often resulting in laminate distortion or 'trapped conditions' during removal from the layup tool.
Innovation Solution
A composite layup tool system with a fixed and movable mold, where the movable mold is displaced towards the fixed mold to break the continuous surface, allowing for the release of the laminate and reduction in cross-sectional size, facilitating extraction from the curing tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the laminate is laid up on an intermediate layup tool with tight radii of curvature and complex contours, then the desired complex shape can be achieved, but the transfer process becomes complicated and the laminate may wrap around the tool causing trapped conditions
Solution Approach 1:
The layup tool is divided into two separate molds: a fixed mold that remains stationary and a movable mold that can be displaced. This segmentation allows the movable mold to be moved away from the fixed mold, creating clearance that enables laminate release and tool extraction without distorting the laminate, thereby solving the trapped condition problem while maintaining complex shape capability
Solution Approach 2:
The movable mold introduces dynamic capability to the previously static layup tool. By enabling the movable mold to displace towards or away from the fixed mold, the system transitions from a rigid structure to a dynamic one that can adapt its configuration during the transfer process, facilitating laminate release and preventing trapped conditions
2Ease of operation
If the laminate is laid up directly on the cure tool, then the transfer process is simplified, but complex contours with tight radii of curvature become difficult or inefficient to achieve
Solution Approach 1:
By segmenting the layup tool into fixed and movable molds, the system creates a intermediate layup capability that preserves complex contour formation while enabling simplified transfer. The segmented structure allows the laminate to be formed on the detailed contours and then released by moving the movable mold, achieving both shape fidelity and transfer ease
3Strength
If the layup tool maintains a large cross-sectional size to support the laminate, then the laminate can be properly supported during layup, but extraction from the female curing tool becomes difficult
Solution Approach 1:
The movable mold enables the layup tool to dynamically change its cross-sectional size. During layup, the molds are positioned to provide full support for the laminate. During extraction, the movable mold displaces to reduce the cross-sectional size, allowing the tool to be withdrawn from the female curing tool without distorting the supported laminate
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 efficient release and transfer of laminates without distortion, reducing the complexity of the transfer process and preventing trapped conditions, thus preserving laminate integrity.
Implementation Method 1
a first plurality of vacuum ports that penetrate through the fixed mold into the first contoured surface and apply suction at the first contoured surface that holds the layup to the first contoured surface
Data Source
AI summary
Systems and methods are provided for adjustable tooling. One embodiment is a method that includes laying up a laminate of fiber reinforced material onto a continuous surface that has a convex profile and that comprises a first contoured surface of a fixed mold of a composite layup tool and a second contoured surface of a movable mold of the composite layup tool. The method also includes displacing the movable mold in a direction that is at least partially towards the fixed mold, breaking the continuous surface and releasing the laminate from the composite layup tool.