Integrated Edge Seals for Vacuum Cauls
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The process of draping a vacuum bag over a caul on a composite part layup and sealing it to a tool is time-consuming, especially for large-scale parts, and requires consumable materials like large vacuum bags and sealant tape, increasing production costs and time.
Innovation Solution
The integration of edge seals around the perimeter of cauls, which form a vacuum tight seal between the caul and the tool, eliminating the need for separate vacuum bags and sealant tape, and allowing the caul and edge seals to be installed and sealed more quickly, with the edge seals being permanently attached to the caul and removably attached to the tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible vacuum bag is placed over the caul and sealed around its periphery using sealant tape, then a vacuum tight seal is achieved, but the process becomes time-consuming and requires consumable materials that increase production costs
Solution Approach 1:
The edge seal integrates multiple functions into a single component: it provides the vacuum barrier, the sealing mechanism, and the attachment to the caul all in one element. This eliminates the need for separate vacuum bags and sealant tape, reducing the number of steps required to achieve a vacuum tight seal while maintaining reliability
Solution Approach 2:
The edge seal is pre-attached to the caul perimeter before the caul is placed on the part layup. This preliminary preparation allows for faster installation since the sealing component is already in position and does not require draping or separate attachment during the manufacturing process
2Reliability
If a flexible vacuum bag is placed over the caul and sealed using sealant tape, then a vacuum tight seal is achieved, but consumable materials are required that increase production costs
Solution Approach 1:
The edge seal is designed to be permanently attached to the caul and reused across multiple production cycles. The caul with its integrated edge seal becomes a reusable tool rather than a single-use consumable, eliminating the need for continuous purchase of vacuum bags and sealant tape while maintaining vacuum seal integrity
Solution Approach 2:
Instead of discarding vacuum bags and sealant tape after each use, the edge seal is recovered and reused with each caul. This transforms a consumable material system into a durable tool system, significantly reducing material consumption and production costs
3Reliability
If large vacuum bags are draped and positioned over cauls, then a vacuum seal is formed, but the process is time-consuming and reduces production rates
Solution Approach 1:
The edge seal is pre-attached to the caul perimeter before the caul is placed on the part layup. This preliminary preparation eliminates the time-consuming steps of draping and positioning large vacuum bags during production, allowing for faster installation while ensuring proper vacuum seal formation
Solution Approach 2:
The sealing function is segmented from the bulk vacuum bag material and concentrated at the edge perimeter where it is needed. This edge-focused approach eliminates the need to handle and position large vacuum bags, reducing the time and complexity of the sealing process while maintaining vacuum integrity
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 reduces production costs by minimizing consumable materials, decreases processing time, and increases production rates by eliminating the need for draping and positioning large vacuum bags, while allowing for efficient and quick installation of the caul over the part layup.
Implementation Method 1
an edge seal extending around a perimeter of the caul and configured to form a substantially vacuum tight seal between the caul and the tool
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An apparatus and method for sealing at least first and second cauls (60a, 60b) over a composite barrel part layup (50) on a mandrel (52), comprising: a first edge seal (62a) extending around a perimeter (76) of the first caul (60a) and configured to form a vacuum tight seal between the first caul (60a) and the mandrel (52); and a second edge seal (62b) extending around a perimeter (76) of the second caul (60b) and configured to form a vacuum tight seal between the second caul (60b) and the mandrel (52), wherein the first and second edge seals (62a, 62b) overlap and are configured to form a vacuum tight seal between the first and second cauls (60a, 60b).