Moulding Tool Zone Temperature Control

Solution Overview

Problem

Current moulding techniques, particularly with autoclaves, struggle to control material properties of articles with varying thicknesses and complex designs, leading to inconsistencies in material properties due to uneven heat transfer and curing rates, which increases production time and energy inefficiency.

Innovation Solution

A tooling system that allows for continuous local heating and cooling of tool zones, equipped with sensors to monitor material properties in real-time, enabling direct feedback control of heat transfer to achieve consistent material properties across different areas of the article.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If autoclaves are used to control material properties of articles with varying thickness, then material properties can be regulated, but production time increases and energy efficiency decreases

Engineering Contradiction:

Improvematerial properties controlVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The tool is divided into multiple independently controllable zones, each capable of maintaining different temperatures. This allows simultaneous processing of different thickness sections at optimal temperatures, eliminating the need for gradual cooling and significantly reducing production time while maintaining material property control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each zone of the tool can be independently temperature-controlled according to the specific requirements of different article sections. This local quality control enables precise management of material properties in varying thickness areas without compromising overall production efficiency.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If autoclaves are used to control material properties of articles with varying thickness, then material properties can be regulated, but energy consumption increases

Engineering Contradiction:

Improvematerial properties controlVSAvoidenergy efficiency

Core Design Contradiction:

Manufacturing precisionVSUse of energy by stationary object

Solution Approach 1:

The tool is divided into multiple independently controllable zones, each capable of maintaining different temperatures. This allows simultaneous processing of different thickness sections at optimal temperatures, eliminating the need for gradual cooling and significantly reducing production time while maintaining material property control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each zone of the tool can be independently temperature-controlled according to the specific requirements of different article sections. This local quality control enables precise management of material properties in varying thickness areas without compromising overall production efficiency.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If gradual cooling is used to control crystallinity in thick and thin parts, then material properties are improved, but production time increases

Engineering Contradiction:

Improvecrystallinity controlVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The tool is divided into multiple independently controllable zones, each capable of maintaining different temperatures. This allows simultaneous processing of different thickness sections at optimal temperatures, eliminating the need for gradual cooling and significantly reducing production time while maintaining material property control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cooling process is made dynamic and controllable through independent zone management. Each zone can apply cooling at the optimal rate for its specific thickness, allowing rapid processing without sacrificing crystallinity control, thereby reducing production time while maintaining material quality.

Inventive Principle:

Principle #15Dynamics

4Shape

If single large article design is used, then design integrity is maintained, but control over material properties in different sections is compromised

Engineering Contradiction:

Improvedesign integrityVSAvoidmaterial properties control

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The tool is divided into multiple independently controllable zones, each capable of maintaining different temperatures. This allows simultaneous processing of different thickness sections at optimal temperatures, eliminating the need for gradual cooling and significantly reducing production time while maintaining material property control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each zone of the tool can be independently temperature-controlled according to the specific requirements of different article sections. This local quality control enables precise management of material properties in varying thickness areas without compromising overall production efficiency.

Inventive Principle:

Principle #3Local quality

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 system ensures the production of articles with specific, repeatable material properties by independently controlling temperature and crystallinity in various zones, reducing production time and energy consumption while maintaining design integrity.

Implementation Method 1

By continuously being able to locally heat and/or cool the tool zones and thereby control the heat transfer into and out of the article within the tool

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

The sensed property may be one of: temperature, dielectric constant, strain, ultrasonic penetration and hardness

Methodology Applied

Scientific EffectDielectric measurement: Dielectric

Implementation Method 3

The sensed property may be one of: temperature, dielectric constant, strain, ultrasonic penetration and hardness

Methodology Applied

Scientific EffectUltrasonic measurement: Ultrasound

Implementation Method 4

When thermosetting resins are used further complications arise by virtue of the exothermic nature of the process of curing/cross linking

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 5

the rate and temperature at which a material solidifies affects the material properties of the article. This effect usually takes place on a microscopic scale and may for example include such characteristics as the proportion of amorphosity or crystallinity in the final product

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentEP2746020B1Zone control of tool temperature

Publication Date: 2021.12.15 SURFACE GENERATION

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AI summary

A tool system for moulding an article is provided which comprising a tool (100) having a tool surface (104) for forming an article, the tool surface comprising a plurality of tool zones (106). Heating and cooling means (102a) are independently associated with at least some of said tool zones (106). A control means is adapted to control the heating and cooling means (102a) to individually heat or cool the tool zones (106) having heating and cooling means (102a) associated therewith so as to regulate the heat transfer into and out of the article at each tool zone (106) at any particular time throughout the moulding process.