Multi-Segment Composite Mold Vacuum Barrier Alignment
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Solution Overview
Problem
Existing methods for vacuum forming complex composite parts, such as aircraft nacelles, face challenges with vacuum integrity and tool alignment, leading to seam defects and increased complexity and cost, particularly when using multiple tools.
Innovation Solution
A multi-segment tool system where tools mate to form a desired mold profile, with a vacuum barrier encapsulating the preform and tools, eliminating the need for vacuum sealing between tools and ensuring precise alignment through mechanical indexes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple tools are used to form complex composite parts, then the ability to form complex shapes is improved, but vacuum integrity deteriorates due to insufficient sealing between tools
Solution Approach 1:
The tool is divided into multiple separable segments that can be assembled to form complex shapes. Each segment has vacuum sealing surfaces with features like recesses, protrusions, and compliant materials that maintain vacuum integrity at the interfaces between segments, allowing complex part formation without compromising vacuum sealing.
2Adaptability or versatility
If multiple tools are used to form composite parts, then complex shapes can be formed, but alignment precision deteriorates leading to seam defects
Solution Approach 1:
The tool is divided into multiple separable segments with precise mating features including recesses, protrusions, and alignment surfaces that ensure accurate positioning. These segmented features maintain precise alignment between tool sections while allowing the tool to form complex shapes, eliminating seam defects caused by misalignment.
3Manufacturing precision
If mechanical fasteners and gaskets are used to ensure tool alignment and vacuum integrity, then alignment is improved, but device complexity increases
Solution Approach 1:
The vacuum sealing features and alignment features are merged into integrated structures formed as part of the tool segments themselves. Recesses, protrusions, and compliant sealing surfaces are combined in single components that simultaneously provide both alignment and vacuum sealing functions, eliminating the need for separate mechanical fasteners and gasket 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
This approach minimizes seam defects, maintains vacuum integrity, and reduces processing complexity and cost by allowing flexible design adaptation and efficient production of complex shapes with improved alignment accuracy.
Implementation Method 1
a first tool having a top portion and a base; a second tool having an opening, the second tool being capable of receiving the first tool through the opening
Implementation Method 2
Vacuum bag forming is a method of composite fabrication that can be used to form complex shapes using multiple tools. In vacuum bag forming, a vacuum pulls a preform around the contours of a tool.
Data Source
AI summary
A multi-segment tool (10) includes a first tool (30) having first and second surfaces. A second tool (40) has an opening (45) positioned on a first tool in a location other than the first surface or the second surface. The first tool and second tool can receive at least a portion of a preform composite. The first tool can have a vacuum barrier attached to the first surface and to the second surface encapsulating the preform composite and the second tool. A third tool (160) which can receive at least a portion of a preform composite and having an opening (167) can also be positioned on the first tool and be encapsulated by the vacuum barrier.