Involute Conformal Mold for Curing Temperature Control
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Solution Overview
Problem
Existing methods for curing curable compounds in classified environments, such as those used in aircraft and spacecraft manufacturing, face challenges due to variability in curing cycles and quality, noise exposure limits, and compliance with safety standards like C1D1, which current systems like pneumatic energy vortex heaters and heater bars fail to meet.
Innovation Solution
An apparatus and system utilizing an involute conformal mold with regenerative and convective heat transfer channels, integrated with a cure process control system for temperature, humidity, and inerted energy conditioning, allowing for controlled and adaptable curing environments that are portable and flexible, independent of external conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating an entire classified area is used for cure process control, then the curing temperature can be maintained, but the working temperature for employees exceeds the OSHA maximum of 80 degrees Fahrenheit
Solution Approach 1:
The invention divides the heating function into two separate zones: a controlled cure zone where the curable compound is heated to curing temperature, and a separate employee working zone maintained at safe temperatures. The mold acts as a thermal barrier, allowing different temperature conditions in different segments of the same workspace.
Solution Approach 2:
The mold serves as an intermediary thermal barrier between the heat source and the employees. It conducts heat to the curable compound for curing while blocking excessive heat from reaching the employee working area, thus mediating between the heating requirement and safety requirements.
2Temperature
If pneumatic energy vortex heaters are used for cure process control, then the curing temperature can be maintained, but the sound pressure level exceeds the OSHA maximum of 85 decibels
Solution Approach 1:
The invention replaces the pneumatic energy vortex heater system with a radiant heating system that uses infrared radiation and conduction through the mold. This substitution eliminates the high-noise pneumatic components while maintaining effective heating of the curable compound.
3Temperature
If heater bars are used for cure process control, then the curing temperature can be maintained, but the system is not C1D1 compliant and cannot be remotely generated
Solution Approach 1:
The mold acts as an intermediary that can be remotely positioned and controlled. Instead of having heating elements directly in the classified area, the system uses a remotely controllable positioning mechanism to place the mold over the curable compound, allowing C1D1 compliance through remote operation.
4Temperature
If heater blankets are used for cure process control, then the curing temperature can be maintained, but the blanket cannot be applied until tack-free which takes indeterminate time
Solution Approach 1:
The system performs preliminary heating action on the curable compound while it is still in a workable state, before it becomes tack-free. By maintaining the compound at an elevated temperature during the application process, the system eliminates the waiting time and enables immediate subsequent operations.
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 provides consistent and controlled curing processes, ensuring high-quality results while meeting safety standards and reducing environmental impact, improving manufacturing efficiency and reducing costs by maintaining a stable and controlled curing environment.
Implementation Method 1
Each outer channel has an outer path profile configured for regenerative heat transfer to the one or more curable compounds
Implementation Method 2
Each inner channel has an inner path profile configured for convective heat transfer and radiative heat transfer to the one or more curable compounds
Implementation Method 3
The mold body is shaped to provide a shroud over an area covered with the one or more curable compounds on the structure, to isolate the area and to isolate the controlled environment for cure process control
Data Source
AI summary
An apparatus, system and method for isolating a controlled environment for cure process control of application and cure of one or more curable compounds to a structure. The apparatus has an end effector of an involute conformal mold having a mold body shaped to provide a shroud over an area covered with the one or more curable compounds on the structure, to isolate the area and the controlled environment. The mold body has an exterior surface, and an interior surface with a cavity profile corresponding to a desired curable compound shape. The mold body has one or more ports, and a plurality of involute channels with spiral flow paths. The involute channels include outer channel(s) having an outer path profile for regenerative heat transfer to the curable compound(s), and include inner channel(s) having an inner path profile for convective and radiative heat transfer to the curable compound(s).