Composite Mold Venting With Removable Inserts for Complex Filling

Solution Overview

Problem

Complex shapes in compression molded products make removal and filling of composite structures difficult, leading to issues like trapped gases, inconsistent material flow, and undesirable variations in wall thickness.

Innovation Solution

A molding system with removable inserts and vents at the parting line to facilitate consistent material flow and venting during compression molding, allowing gases to escape while maintaining structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If complex shapes are molded in compression molding, then product shape variety is improved, but filling quality and removal ease deteriorate

Engineering Contradiction:

Improveproduct shape varietyVSAvoidfilling quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The mold is divided into multiple segments including a mold base, movable core, and ejector assembly that can be independently positioned and removed. This segmentation allows complex shapes to be molded while maintaining filling quality by enabling precise control over material flow into intricate cavities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold incorporates movable components including a movable core and ejector assembly that can dynamically adjust during the molding process. This dynamic capability enables the mold to adapt to complex geometries while ensuring complete filling and easy removal of the molded product.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If complex shapes are molded in compression molding, then product shape variety is improved, but removal ease deteriorates

Engineering Contradiction:

Improveproduct shape varietyVSAvoidremoval ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The mold is divided into multiple segments including a mold base, movable core, and ejector assembly that can be independently positioned and removed. This segmentation allows complex shapes to be molded while maintaining filling quality by enabling precise control over material flow into intricate cavities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold incorporates movable components including a movable core and ejector assembly that can dynamically adjust during the molding process. This dynamic capability enables the mold to adapt to complex geometries while ensuring complete filling and easy removal of the molded product.

Inventive Principle:

Principle #15Dynamics

3Reliability

If vents are added to the molding system, then gas escape is improved, but device complexity increases

Engineering Contradiction:

Improvegas escapeVSAvoidmolding system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The venting function is merged into the existing mold structure by incorporating vents in the mold base and movable core. This integration allows gas escape without adding separate venting components, thus improving reliability while minimizing the increase in device complexity.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables complete filling of composite structures, reduces material inconsistencies, and improves cycle time by ensuring consistent material flow and minimizing flash formation.

Implementation Method 1

The plurality of vents is on a first side and a second side of the molding system along the parting line... The composite material is vented using the plurality of vents at the parting line during compression of the composite material

Methodology Applied

Scientific EffectGas escape through vents:

Data Source

PatentUS12521914B2Molding system with a plurality of vents

Publication Date: 2026.01.13 THE BOEING CO

AI summary

A molding system for forming a composite structure having trapped volumes is presented. The molding system comprises a plurality of removeable inserts, a bottom tool assembly, and a plurality of vents formed at a parting line of the molding system. Each removeable insert of the plurality of removeable inserts comprises a plurality of pieces configured to be disassembled for removal from the composite structure. Each removeable insert is configured to be placed in contact with the bottom tool assembly.