Composite Patch Transfer Tool with Vacuum and Heating
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Solution Overview
Problem
The challenge lies in maintaining the temperature of composite patches during transfer to a rework area while supporting them to prevent sagging and thermal stresses, especially for high-temperature materials like bismaleimide (BMI) that require precise handling and uniform heating.
Innovation Solution
A tool equipped with a heating blanket and suction holes to maintain uniform temperature and support the patch, ensuring it remains flat and securely positioned during transfer, using a caul plate with vacuum ports to prevent sagging and apply uniform pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the patch is heated to high temperatures for processing BMI materials, then the volatiles are removed and the patch is consolidated, but the patch cools rapidly during transfer and develops thermal stresses
Solution Approach 1:
The patent introduces a support tool as an intermediary between the heating/consolidation process and the transfer operation. This tool maintains the patch at processing temperature during transfer, acting as a thermal mediator that prevents rapid cooling and associated thermal stresses while enabling safe handling of the hot patch material
Solution Approach 2:
The support tool is prepared in advance with heating capability before the patch transfer operation. By pre-establishing the thermal environment on the support tool, the system ensures continuous temperature maintenance throughout the transfer process, preventing the cooling that would otherwise occur during the transition from consolidation to installation
2Manufacturing precision
If the patch is supported during transfer to prevent sagging, then the fit-up is improved, but the handling complexity increases
Solution Approach 1:
The support tool is designed to perform multiple functions: it provides mechanical support to prevent sagging, maintains processing temperature through integrated heating, and facilitates transfer operations. By combining these functions in a single device, the patent reduces overall handling complexity while maintaining manufacturing precision
Solution Approach 2:
The support tool enables dynamic adjustment of temperature parameters during the transfer process. By controlling the thermal state of the patch on the support tool, the system can optimize both the mechanical support characteristics and the thermal properties, achieving precise fit-up without excessive handling complexity
3Reliability
If the patch is heated uniformly, then the thermal stresses are reduced, but the energy consumption increases
Solution Approach 1:
The support tool implements localized heating zones that target specific areas of the patch based on their thermal requirements. By applying heat only where needed rather than uniformly across the entire patch, the system reduces thermal stresses in critical areas while minimizing overall energy consumption
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 tool effectively maintains the patch's temperature and prevents sagging, reducing thermal stresses and ensuring a proper fit during installation, thereby enhancing the integrity and consistency of the composite structure.
Implementation Method 1
A tool is disclosed for transferring a patch to a rework area of a structure... equipped with a heating blanket... to maintain uniform temperature
Implementation Method 2
using a caul plate with vacuum ports to prevent sagging and apply uniform pressure
Implementation Method 3
A tool equipped with a heating blanket and suction holes to maintain uniform temperature and support the patch
Data Source
Figure 1~2
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AI summary
A tool comprises a caul plate having at least one suction hole and a vacuum port fluidly coupled to the suction hole for drawing a patch against the caul plate under vacuum.