High Density Carbon Foam Composite Tooling for CTE Matching
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Solution Overview
Problem
Current composite tooling for carbon fiber composites faces challenges in matching the coefficient of thermal expansion (CTE) with the materials used, leading to issues such as part retention, tool damage, and increased costs due to the scarcity of materials with low CTEs like INVAR and graphite, which are heavy, expensive, and difficult to fabricate.
Innovation Solution
The use of high-density carbon foam (HDCF) in tool bodies, which can have a CTE similar to carbon fiber composites, providing a lightweight, cost-effective, and durable solution for tooling that can maintain dimensional accuracy and resist damage, with densities ranging from 1.0 to 1.8 g/cc and compressive strengths up to 20,000 p.s.i.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional materials like INVAR or graphite are used for tool bodies to match CTE with carbon fiber composites, then dimensional accuracy is improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent applies composite materials by combining carbon foam (providing low CTE matching carbon fiber composites) with structural support materials. This composite approach achieves the desired CTE match for dimensional accuracy while the foam's cellular structure provides weight reduction compared to solid conventional materials like INVAR or graphite.
Solution Approach 2:
The patent utilizes porous carbon foam material whose cellular structure provides both low density (reducing tool weight) and appropriate CTE characteristics (matching carbon fiber composites). The porous structure allows weight reduction while maintaining the thermal expansion properties needed for dimensional accuracy.
2Manufacturing precision
If conventional materials like INVAR or graphite are used for tool bodies to match CTE with carbon fiber composites, then dimensional accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The composite of carbon foam and structural materials provides a cost-effective alternative to expensive conventional materials like INVAR or graphite. The carbon foam component is more economically viable while still achieving the required CTE match for dimensional accuracy through proper material selection and formulation.
Solution Approach 2:
The porous carbon foam structure offers a cost-effective solution compared to solid conventional materials. The foam structure reduces material usage and manufacturing complexity while maintaining appropriate CTE properties, thereby reducing overall manufacturing cost while preserving dimensional accuracy.
3Weight of stationary object
If high density carbon foam is used in tool bodies, then weight is reduced and cost decreases, but structural strength may be compromised
Solution Approach 1:
The patent employs composite construction where carbon foam provides the lightweight matrix with appropriate CTE, while structural support elements (such as ribs, struts, or embedded reinforcement) provide the necessary structural strength. This composite approach decouples the weight reduction function from the structural support function, allowing both objectives to be achieved simultaneously.
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
HDCF tooling offers a lightweight, cost-effective, and durable solution that matches the CTE of carbon fiber composites, reducing tooling costs and lead times, while maintaining dimensional accuracy and resisting damage, thus improving the production of composite parts with precise dimensions and properties.
Implementation Method 1
HDCF tooling offers a lightweight, cost-effective, and durable solution that matches the CTE of carbon fiber composites, reducing tooling costs and lead times, while maintaining dimensional accuracy
Data Source
AI summary
Tools for the forming of composite parts from composite forming materials, having tool bodies that comprise, at least in part, high density carbon foam where a surface of the high density carbon foam may comprise a tool face or support tool face materials. The tools of the present invention may be lighter, more durable, and less costly to produce and/or use than conventional tools used for the production of composite parts, particularly those tools used for the production of carbon composites. Additionally, such tools may be reusable, repairable, and more readily modifiable.