Core Support Structure Using Frozen Fluid for Residue-Free Machining
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Solution Overview
Problem
Conventional methods for securing core materials during machining processes, such as honeycomb cores, face challenges with adhesion loss, damage, and residue contamination, particularly when using pressure sensitive adhesives and thermoplastics.
Innovation Solution
A core support system featuring a thermally conductive member with a fluid-saturatable engagement layer that freezes to securely hold the core material, allowing for machining and easy release without damage or residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressure sensitive adhesives are used to secure core materials, then the core material can be held in place during machining, but adhesion is lost during machining processes and residue is left on the core material
Solution Approach 1:
The patent utilizes phase transitions of a fluid (liquid to solid to liquid) to secure and release core materials. The fluid is applied in liquid form, frozen to solid form to secure the core material during machining, then melted back to liquid form for clean release without residue.
Solution Approach 2:
The patent replaces mechanical adhesion systems (pressure sensitive adhesives, thermoplastics, cure-on products) with a thermal system using frozen fluid. This substitution eliminates the need for chemical adhesives that leave residue, using instead the physical state change of water or other fluids to create secure yet cleanable attachment.
2Strength
If conventional adhesive methods are used, then core materials can be secured to support structures, but a separate cure cycle is required and the process becomes complex
Solution Approach 1:
The patent uses the simple phase transitions of water or other fluids (freeze/thaw) to create securement and release mechanisms, eliminating the need for complex cure cycles associated with adhesives and epoxies. The process requires only temperature control rather than chemical curing processes.
Solution Approach 2:
The frozen fluid system is self-service in that it provides both securement and release functions through its inherent physical properties. The same frozen fluid that secures the core material automatically releases it when melted, eliminating the need for separate removal mechanisms or processes.
3Manufacturing precision
If traditional subtractive manufacturing processes are used to machine core materials, then materials can be removed, but it is difficult to properly secure the core materials to a support structure
Solution Approach 1:
The patent employs frozen fluid to reliably secure core materials to support structures during machining operations. The frozen state provides firm attachment that maintains positioning accuracy, while the liquid state allows for easy removal after machining is complete.
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 effectively secures core materials during machining, preventing adhesion loss and contamination, and simplifies the process by eliminating the need for a separate cure cycle, while ensuring the core material is not damaged during removal.
Implementation Method 1
the thermally conductive member configured to remove heat energy from a fluid disposed on or within the at least partially fluid-saturatable engagement layer to reduce the temperature of the fluid to solidify the fluid
Implementation Method 2
reduce the temperature of the fluid to solidify the fluid and secure the at least one material to the support portion
Implementation Method 3
an insulating frame defining a recess, a thermally conductive insert disposed within the recess of the insulating frame
Data Source
AI summary
A core support system includes a support structure. The support structure includes a frame and a support member having a saturatable engagement layer disposed over the frame. A method of machining a core material incudes applying a fluid to an engagement layer of a support structure and saturating the engagement layer with the fluid, disposing a core material on the engagement layer, causing the fluid to freeze to secure to the core material to the support structure, machining the core material, melting the frozen fluid to release the core material from the support structure, and removing the core material from the engagement layer.