Mould Tool Heating Elements with Integrated Fluid Conduits
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Solution Overview
Problem
Mould tools used in fibre-reinforced composite manufacturing face challenges in efficiently controlling temperature and reducing moulding cycle time due to complex conduit systems, non-uniform heating, and health and safety hazards associated with fluid handling and umbilical systems.
Innovation Solution
A mould tool comprising multiple parts with integrated conduits for thermal energy transfer, self-contained heating and cooling systems, and electrical connections that allow for independent temperature control and continuous power supply, enabling rapid assembly and disassembly, and reducing the need for umbilical systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hot water or oil is fed through conduits from an external heater to heat multiple tool parts, then the tool parts can be heated for curing resin, but it becomes difficult to run conduits through all parts and requires draining fluid before disassembly, adding delay to moulding cycle time
Solution Approach 1:
The heating system is segmented into independent heating elements within each tool part, allowing each part to be heated independently without requiring a continuous fluid conduit system through all parts. This eliminates the time-consuming fluid draining and reconnection processes during tool disassembly and reassembly.
Solution Approach 2:
The heating function is extracted from the external fluid-based heating system and integrated directly into each tool part through self-contained heating elements. This removes the dependency on external fluid conduits and the associated time losses during tool part disassembly and reassembly.
2Adaptability or versatility
If multiple tool parts are assembled to define the exterior surface of the moulded part, then complex components can be formed, but the conduit system becomes complex and requires disconnecting and re-connecting at every stage
Solution Approach 1:
The heating system is divided into independent segments within each tool part, allowing each part to function autonomously. This segmentation eliminates the need for complex interconnected conduit systems while maintaining the ability to form complex multi-part moulded components.
Solution Approach 2:
Each tool part contains its own self-contained heating element that does not require external fluid conduits or connections to other parts. This self-service approach simplifies the overall system while enabling complex multi-part tool configurations.
3Temperature
If electrical channels or cartridges are used for heating, then thermal energy can be supplied to the moulded part, but non-uniform heating occurs due to point introduction of thermal power
Solution Approach 1:
The heating function is extracted from concentrated electrical cartridges and redistributed through the fluid conduit system that contacts multiple surfaces of the tool part. This extraction and redistribution of the heating function enables uniform thermal distribution across the entire tool part surface.
Solution Approach 2:
A fluid intermediary is introduced to transfer thermal energy uniformly across the tool part surfaces. The fluid acts as a mediator that distributes heat evenly throughout the tool part, eliminating the non-uniform heating caused by point-source electrical cartridges.
4Reliability
If umbilical systems are used to maintain fluid feed connections during tool assembly movement, then continuous fluid supply can be maintained, but the systems are impractical due to size and complexity and risk being mechanically trapped
Solution Approach 1:
The fluid heating system is extracted from the tool parts and replaced with self-contained electrical heating elements integrated into each tool part. This extraction eliminates the need for umbilical fluid connections during tool movement, removing the associated complexity and mechanical trapping risks.
Solution Approach 2:
The mechanical fluid connection system (umbilicals) is replaced with an electrical heating system that requires no physical fluid conduits during tool movement. This substitution eliminates the complexity and mechanical trapping risks associated with umbilical systems while maintaining reliable heating functionality.
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 moulding cycle time, enhances temperature control and safety, and allows for continuous operation by maintaining fluid within conduits during assembly and disassembly, eliminating the need for frequent fluid handling and minimizing the risk of leakage and contamination.
Implementation Method 1
a heating element configured to heat fluid contained within the conduit; and an electrical input configured to supply electricity to the heating element to heat the fluid
Implementation Method 2
a conduit contained within the tool part being configured to transfer thermal energy between fluid contained in the conduit and the tool part body
Data Source
Figure 1~2A
Figure 2B~3A
Figure 3B~4
AI summary
A mould tool comprising a plurality of tool parts which can be assembled to define an exterior surface of a moulded part, at least one of the tool parts comprising: a tool part body for defining part of the exterior surface of the moulded part; a conduit being configured to transfer thermal energy between fluid contained in the conduit and the tool part body; a heating element configured to heat fluid contained within the conduit; and an electrical input configured to supply electricity to the heating element to heat the fluid so as to heat the tool part body.