Layered Tool Temperature Control with Thermal Isolation
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Solution Overview
Problem
Existing tools for molding metal, plastics, and composite materials face inefficiencies due to large, expensive autoclaves that cannot dynamically control temperature across workpieces, and previous solutions involving metal tool pins with integrated heating/cooling fluids are complex and inefficient due to thermal conductivity issues and high thermal inertia.
Innovation Solution
A layered tool design with a temperature control surface, a mid-temperature exhaust region, and a thermally isolated layer for electronics, allowing for precise temperature control and reduced thermal mass, enabling quick adjustments and efficient heating/cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal tool pins with high thermal conductivity are used for heating/cooling fluid delivery, then temperature control capability is improved, but thermal inertia increases and response time deteriorates
Solution Approach 1:
The tool pin is segmented into distinct functional layers: a first layer (tool face) for temperature control, a second layer (exhaust region) for fluid discharge, and a third layer (electronics region) for control systems. This segmentation allows each layer to be optimized independently, with the first layer having minimal thermal mass for rapid response while other layers handle supporting functions.
Solution Approach 2:
The heating/cooling fluid delivery system is extracted from the traditional integrated metal pin design and repositioned to terminate in the first layer, with the fluid source and control electronics located in the third layer. This extraction reduces the thermal path length and eliminates unnecessary thermal mass in the fluid delivery pathway.
2Reliability
If remote heating/cooling units with fluid supply lines are used, then electronics protection from extreme temperatures is improved, but system complexity and energy loss increase
Solution Approach 1:
The third layer (electronics region) is nested within the tool structure, positioned to be thermally isolated from the first layer (tool face) by the second layer (exhaust region). This nested arrangement protects electronics from extreme temperatures while maintaining a compact, integrated tool design rather than using separate remote units.
Solution Approach 2:
The tool adopts a three-layer vertical architecture where the electronics are positioned in the third layer, thermally isolated from the temperature-controlled first layer. This dimensional separation in the vertical axis allows electronics protection without requiring complex lateral routing of fluid supply lines.
3Quantity of substance
If bulky tool pins with fluid channels are machined, then fluid delivery capability is improved, but thermal mass increases and thermal agility deteriorates
Solution Approach 1:
The tool pin is divided into functional layers with the first layer optimized for minimal thermal mass and rapid temperature response. Fluid channels are concentrated in specific regions (second layer for exhaust, third layer for supply) rather than throughout the entire pin structure, reducing unnecessary thermal mass while maintaining fluid delivery capability.
Solution Approach 2:
Different regions of the tool pin are given different properties: the first layer has minimal thickness and thermal mass for rapid temperature changes, while the second and third layers provide fluid delivery pathways and structural support. This local differentiation optimizes both thermal agility and fluid delivery without compromise.
4Ease of operation
If single temperature curing in autoclave is used, then process simplicity is improved, but ability to vary temperature across workpiece deteriorates
Solution Approach 1:
The tool face is segmented into multiple independently controllable zones corresponding to different regions of the workpiece. Each zone can be heated or cooled independently through the layered structure, enabling spatial temperature variation while maintaining a relatively simple tool architecture.
Solution Approach 2:
The temperature control system is made dynamic by allowing independent temperature adjustment in different zones of the tool face. The layered structure enables rapid temperature changes and independent control of different regions, transforming the static single-temperature autoclave process into a dynamic multi-zone system.
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
The tool achieves high thermal agility, allowing for independent temperature control across zones, reducing energy consumption and tool complexity, while protecting electronics from extreme temperatures.
Implementation Method 1
a first layer defining a tool face, and a temperature control surface opposite the tool face... allows the most extreme temperatures to be isolated to the first layer
Implementation Method 2
a fluid injector comprising an inlet and an outlet, which injector extends from the third layer, through the second layer to the first layer such that the outlet is proximate the temperature control face
Implementation Method 3
a second layer defining a second layer fluid chamber in fluid communication with the temperature control surface and an exhaust port to exhaust fluid from the tool
Data Source
AI summary
A tool (100) comprises a plurality of layers (102, 104, 106) which are arranged to provide a thermally agile tool face (110) and to protect control circuitry and delicate components (150) from excessive temperatures.