Modular Tooling Plates for Variable-Size Laminate Consolidation
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Solution Overview
Problem
Current methods for consolidating thermoplastic sheets into structural panels are limited by the size constraints of platen presses, requiring multiple tools or presses for different laminate sizes, which is cumbersome and costly, and lacks high productivity in the aircraft industry.
Innovation Solution
A modular tooling system with interchangeable plates and a common base member allows for the consolidation of laminates of various sizes using a single master tool, reducing tooling costs and cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple platen presses or tools are used to handle different laminate sizes, then the ability to process various laminate sizes is improved, but device complexity and tooling costs increase
Solution Approach 1:
The patent implements a universal tooling system where a single master tool can process laminates of various sizes through interchangeable modular components. The base member with standardized cavity dimensions combined with replaceable plate assemblies allows one tool to perform multiple functions across different laminate size requirements, eliminating the need for multiple dedicated presses or tools.
Solution Approach 2:
The tooling system is segmented into modular components including a base member, frame, and interchangeable plate assemblies. This segmentation allows flexible reconfiguration of the tooling system to accommodate different laminate sizes by simply replacing plate components rather than changing entire tools or presses.
2Adaptability or versatility
If multiple platen presses or tools are used to handle different laminate sizes, then the ability to process various laminate sizes is improved, but manufacturing costs increase
Solution Approach 1:
The universal master tool design reduces manufacturing costs by consolidating multiple tool functions into a single system. Instead of purchasing and maintaining multiple specialized presses or tools for different laminate sizes, the organization invests in one versatile tooling system with modular components that can be reconfigured for various production needs.
Solution Approach 2:
The patent merges the functionality of multiple dedicated tools into a single integrated master tool system. By combining the base structure, frame, and interchangeable plate assemblies into one system, the organization eliminates redundant tooling investments and reduces overall manufacturing costs while maintaining the ability to process various laminate sizes.
3Productivity
If traditional consolidation methods are used, then structural panels can be produced, but productivity is reduced due to cumbersome tooling changes
Solution Approach 1:
The tooling system incorporates dynamic reconfigurability through quickly interchangeable plate assemblies. Rather than requiring time-consuming tool changes, the system allows rapid replacement of plate components to adapt to different laminate sizes, maintaining operational flow and productivity while improving ease of operation.
Solution Approach 2:
The modular plate assemblies are designed to be pre-configured and ready for quick installation. This preliminary preparation of interchangeable components enables rapid tooling changes without disrupting the production workflow, thereby maintaining high productivity while significantly improving the ease of operation compared to traditional fixed tooling systems.
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
Enables efficient and cost-effective production of thermoplastic laminates in different sizes and shapes by utilizing a single tool, enhancing productivity and reducing tooling complexity.
Implementation Method 1
a press member configured to compress the work piece between the planar working surface and the press member
Implementation Method 2
Consolidation of thermoplastic sheets into solid, substantially flat panels of useful thicknesses
Data Source
AI summary
A modular tooling arrangement includes a base member comprising a planar working surface, a frame circumscribing a first cavity at least partially defined by the planar working surface, and a plurality of plates configured to be received in the first cavity for forming a second cavity of a desired shape and size. The plurality of plates at least partially define the second cavity configured to receive a work piece. The plurality of plates may be replaced with plates of various sizes to vary at least one of the size and shape of the second cavity.