Mould Tools With Polymer Foam Core And Resin Skin
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Solution Overview
Problem
Conventional mould tools for curable resin composite materials face limitations in accuracy and scalability due to material brittleness, combustibility, and expansion issues, particularly when producing large and complex tools.
Innovation Solution
A mould tool comprising a series of tool body sections with an inner polymer foam core and an outer fibre-reinforced resinous material skin, stacked and bonded to form a robust and thermally stable structure, which prevents expansion and collapse under elevated temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional materials (carbon, glass, or ceramic foam) are used for the main body of mould tools, then certain advantages are offered, but the materials are brittle and vulnerable to cracking and delamination from the tool skin
Solution Approach 1:
The patent applies composite materials by combining polymer foam core with fibre-reinforced resinous material skins to create a multi-layered structure. This composite construction provides both structural integrity and resistance to cracking and delamination, as the fibre reinforcement strengthens the bond between layers and distributes stresses more effectively than conventional single-material foams.
Solution Approach 2:
The patent implements a nested structure where tool body sections are stacked and interconnected, with each section containing an inner foam core within an outer skin. This nested arrangement allows multiple functional layers to work together, with the outer skin protecting the inner core while maintaining overall structural strength and reliability.
2Strength
If carbon foam is used for the main body, then certain advantages are offered, but concerns exist regarding combustibility and moisture absorption
Solution Approach 1:
The patent replaces expensive and problematic carbon foam with polymer foam that offers comparable structural properties without the combustibility and moisture absorption issues. The polymer foam serves as a safer, more stable alternative that maintains tool integrity under various environmental conditions.
Solution Approach 2:
By using fibre-reinforced polymer foam composites, the patent achieves the necessary structural strength while eliminating the harmful properties of carbon foam. The fibre reinforcement provides mechanical strength equivalent to or exceeding carbon foam, while the polymer matrix resists combustion and moisture absorption.
3Ease of manufacture
If conventional hand-shaped or machined patterns are used to produce mould tools, then the process is traditional and established, but there is a limit to how accurately the tool skin can be moulded
Solution Approach 1:
The patent applies preliminary action by pre-forming the tool body sections with accurate geometries before applying the tool skin. The stacked tool body sections provide a precise underlying structure that enables accurate moulding, eliminating the need to rely solely on the accuracy of hand-shaped or machined patterns.
Solution Approach 2:
The patent divides the tool body into multiple stackable sections, each contributing to the overall accuracy. This segmentation allows for modular manufacturing where each section can be precisely formed and then assembled, achieving higher overall precision than conventional single-piece patterns.
4Ease of manufacture
If conventional mould tools are produced for small scale tooling, then the process is manageable, but they do not adequately cater for the production of complex, relatively large mould tools
Solution Approach 1:
The patent applies segmentation by dividing large tool bodies into multiple smaller, stackable sections. Each section can be manufactured using conventional small-scale processes, then assembled into a large complex tool. This modular approach maintains manufacturing manageability while enabling the production of large-volume tools that would be impossible to create as single pieces.
Solution Approach 2:
The nested structure of stacked tool body sections allows small, manageable components to be combined into a large integrated tool system. Each nested section contributes to the overall volume and complexity while maintaining the ease of manufacturing individual smaller units.
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 solution enables the creation of large, accurate, and structurally stiff mould tools with reduced risk of delamination and deformation, suitable for high-temperature applications, and facilitates the production of complex composite components.
Implementation Method 1
even with the use of sophisticated computer modeling and predictions of the thermal expansion and chemical shrinkage of the materials used in the tool skin as they cure
Implementation Method 2
The resinous material is preferably a fibre-reinforced resinous material and may comprise a cured or curable resinous material, reinforced with fibre reinforcement such as one or more of carbon fibre, glass fibre, Aramid and the like
Data Source
AI summary
A mould tool (10) for moulding mouldable material, the mould tool comprises a tool body (12) having a plurality of tool body sections (14), at least two of which comprise an inner polymer foam core (16) within an outer skin (18) of resinous material and are stacked one above the other, the tool (10) further comprises a mould skin (20) extending over the body (12) to provide a mould surface (22) on which mouldable material can be moulded. A method of manufacturing such a mould tool and a tool body are also provided.