Granular Mold and Trim Tool for Vacuum-Held Composite Parts
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Solution Overview
Problem
Conventional methods for manufacturing composite parts using vacuum fixtures require separate tools for layup, curing, and trimming, which are costly, time-consuming, and difficult to repair, leading to inefficiencies and imperfections due to the need for multiple tools and complex alignment processes.
Innovation Solution
A method and apparatus using a granulated material composed of particulate and binding materials, which can be used to create repairable tool surfaces, allowing for both layup and trimming/machining operations without the need for separate tools, by forming the material into a vacuum fixture with cavities and passages for vacuum pressure distribution, and using it to secure parts with enhanced friction and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate tools are used for layup and trimming operations, then each operation can be performed with dedicated equipment, but the number of tools increases, cost increases, and time consumption increases
Solution Approach 1:
The patent combines layup and trimming operations into a single integrated tool. The tool includes a layup surface for forming composite parts and a trimming surface with a cavity that receives the formed part for trimming. This eliminates the need for separate layup and trimming tools, reducing the number of tools required while maintaining operational reliability through a unified design.
Solution Approach 2:
The integrated tool performs multiple functions: it serves as both a layup tool for forming composite parts and a trimming tool for cutting the parts to final dimensions. The tool includes a layup surface for material formation and a trimming surface with vacuum channels for securing and trimming the part, enabling one tool to replace multiple specialized tools.
2Reliability
If conventional vacuum fixtures are used, then vacuum pressure can secure the part, but the tool surface is difficult and expensive to repair when worn or damaged
Solution Approach 1:
The patent changes the physical state and properties of the tool surface by using a granulated material mixture (such as epoxy mixed with granulated aluminum oxide or silicon carbide) that can be applied to repair worn or damaged areas. This material cures to restore the vacuum seal surface, maintaining vacuum holding reliability while providing an easy and inexpensive repair method compared to conventional machining or replacement.
3Manufacturing precision
If tight tolerances are required for part size and shape, then precise positioning and alignment are needed, but the alignment process becomes time-consuming and complex
Solution Approach 1:
The patent combines layup and trimming operations in a single integrated tool, which eliminates the need for transferring parts between tools and reduces alignment requirements. The tool includes a layup surface for forming parts and a trimming surface with a cavity that receives the formed part, allowing direct trimming without complex alignment procedures while maintaining tight tolerances.
Solution Approach 2:
The patent replaces mechanical alignment systems with a vacuum-based securing system. Vacuum pressure is applied through channels in the trimming surface to secure the formed part in place during trimming operations, eliminating the need for mechanical clamps, fixtures, or alignment tools while maintaining precise positioning and tight tolerances.
4Ease of manufacture
If multiple separate tools are used, then each tool can be optimized for its specific function, but the total manufacturing cost and time increase
Solution Approach 1:
The patent combines layup and trimming operations into a single integrated tool, eliminating the need for multiple separate tools. The tool includes a layup surface for forming composite parts and a trimming surface with a cavity and vacuum channels for securing and trimming parts. This integration reduces the number of tools required, lowers manufacturing costs, and improves productivity by eliminating tool transfers and setup time.
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 approach reduces manufacturing costs and time by enabling a single tool to perform multiple functions, improving part precision and reducing the need for frequent tool replacement, with the granulated material providing a durable and easily repairable surface for machining and trimming.
Implementation Method 1
secure parts with enhanced friction and sealing
Implementation Method 2
forming the material into a vacuum fixture with cavities and passages for vacuum pressure distribution
Data Source
AI summary
An apparatus for manufacturing a part, where the apparatus includes a granular media made of a particulate material and a binding material, where at least a portion of the granular media being formed as a surface of a layup tool.