Flexible Wall Tooling for Non-Uniform Pressure Control
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Solution Overview
Problem
Conventional pressurized bladders are limited to applying uniform pressure to surfaces, failing to independently control pressure levels and forces on different portions of an object, which is necessary for complex shapes and processes like composite curing.
Innovation Solution
A pressurizable tooling device with a flexible wall and a contact member allows for independent control of pressure and force levels on different portions of a surface by using a combination of internal bladder pressure and external forces applied through a contact member, enabling variations of up to 200% difference in pressure/force between areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a pressurized bladder is used to apply pressure to a surface, then uniform pressure distribution is achieved, but the ability to apply different pressure levels to different portions of the surface is lost
Solution Approach 1:
The bladder is divided into multiple independently controllable chambers or zones, each capable of receiving different pressure levels. This segmentation allows different portions of the bladder to exert different pressures on corresponding portions of the workpiece surface, resolving the contradiction between uniform pressure stability and adaptable pressure distribution control.
Solution Approach 2:
Different regions of the bladder are designed with different local properties, such as varying stiffness, thickness, or pressure responsiveness. This enables specific zones to apply tailored pressure levels to match the local requirements of the workpiece surface, achieving both overall stability and local adaptability.
2Stability of the object's composition
If a rigid support structure is used to maintain bladder shape, then structural stability is improved, but the ability to conform to irregular surfaces is reduced
Solution Approach 1:
The bladder is constructed from flexible materials that can conform to irregular surfaces while maintaining structural integrity. The flexible shell design allows the bladder to adapt its shape to match the workpiece surface contours, eliminating the need for rigid support structures that would prevent surface conformity.
Solution Approach 2:
The bladder design incorporates dynamic elements that allow it to adjust its shape and stiffness in response to surface variations. This dynamic adaptability enables the bladder to maintain stability while conforming to irregular surfaces, resolving the contradiction between shape stability and surface conformity.
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 solution enables precise control of pressure and force distribution on complex surfaces, preventing issues like bridging and allowing for higher quality processing, cost savings, and expanded processing capabilities, including the ability to apply uniform or non-uniform pressure as needed.
Implementation Method 1
applying a first force to a first portion of a first surface of the object using the first flexible wall, wherein the applying the first force comprises pressurizing the bladder
Implementation Method 2
applying a third force onto a third portion of a second surface of the object using a second flexible wall, the third portion of the second surface corresponding to a second contact member, wherein applying the third force comprises applying an external force to the second contact member
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
Provided are methods and apparatuses for processing objects by applying different forces and/or pressure levels to different portions of surfaces of these objects. An apparatus may include a flexible wall and a contact member. In some arrangements, the flexible wall forms a bladder such that the contact member is disposed inside the bladder. During operation, the flexible wall may be pressed against an object using a pressure differential across the wall (e.g., by pressurizing the bladder). This creates a first force acting on a first portion of the object surface. Furthermore, the contact member may be forced against the flexible wall and apply a second force to a second portion of the object surface through the wall. The second portion of the object surface may be a subset of the first portion or an entirely different portion.