Phase Change Composite Forming Tool
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing forming tools for composite parts face challenges in removing complex geometries without damaging the parts and ensuring uniform pressure application during autoclave curing, often requiring destruction of the tool and inadequate pressure distribution.
Innovation Solution
The development of forming tools that are rigid at lower temperatures for layup and become pliable at higher temperatures, allowing for pressure application during curing and easy removal post-curing, utilizing phase change materials and flexible enclosures with an internal pressurizable compartment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a forming tool is made rigid to maintain shape during layup, then the laminate achieves desired shape, but the tool cannot be removed easily from complex geometries after curing
Solution Approach 1:
The forming tool transitions from a static rigid state to a dynamic pliable state through temperature-induced phase change. The tool is rigid at room temperature for layup, then becomes pliable when heated above the phase change temperature, enabling easy removal from complex geometries without damaging the cured composite part.
Solution Approach 2:
The forming tool utilizes phase transition of the phase change material (PCM) embedded within it. Below the phase change temperature, the PCM is solid and provides rigidity. Above the phase change temperature, the PCM melts and allows the tool to become pliable, facilitating removal from complex geometries.
2Strength
If a forming tool is made rigid to maintain structural integrity, then the tool provides stable support, but pressure cannot be uniformly applied to the laminate during autoclave curing
Solution Approach 1:
The forming tool utilizes phase transition of the phase change material (PCM) embedded within it. Below the phase change temperature, the PCM is solid and provides rigidity. Above the phase change temperature, the PCM melts and allows the tool to become pliable, facilitating removal from complex geometries.
Solution Approach 2:
The forming tool's physical properties change with temperature. At curing temperatures above the phase change point, the tool becomes pliable to conform to the laminate and apply uniform pressure. At room temperature, the tool returns to its rigid state for structural support during layup.
3Ease of operation
If a forming tool is destroyed to remove it from complex geometries, then the tool can be removed, but the cost and time of generating new tools increases
Solution Approach 1:
The forming tool transitions from a static rigid state to a dynamic pliable state through temperature-induced phase change. The tool is rigid at room temperature for layup, then becomes pliable when heated above the phase change temperature, enabling easy removal from complex geometries without damaging the cured composite part.
Solution Approach 2:
Instead of destroying the forming tool for removal, the invention allows the tool to be recovered intact by temporarily changing its physical state through heating. The tool is discarded in its rigid state for removal difficulty, but recovered in its pliable state for easy removal, enabling reuse and reducing overall time and cost.
4Manufacturing precision
If pressure is applied to the laminate during curing, then the laminate achieves desired density and shape, but the forming tool may deform or fail under the pressure
Solution Approach 1:
The forming tool's physical properties change with temperature. At curing temperatures above the phase change point, the tool becomes pliable to conform to the laminate and apply uniform pressure. At room temperature, the tool returns to its rigid state for structural support during layup.
Solution Approach 2:
The forming tool utilizes phase transition of the phase change material (PCM) embedded within it. Below the phase change temperature, the PCM is solid and provides rigidity. Above the phase change temperature, the PCM melts and allows the tool to become pliable, facilitating removal from complex geometries.
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 the reuse of forming tools, reduces costs and time, and facilitates the removal of composite parts without damage by applying uniform pressure and retracting from the cured part, ensuring desired shapes and preventing deformation.
Implementation Method 1
elements of phase change material that provide rigidity to the body below a threshold temperature, and that exhibit a phase change at the threshold temperature causing the body to become pliable
Implementation Method 2
The body also includes flexible material that encloses the elements of phase change material
Implementation Method 3
an air pressure device configured to pressurize and depressurize an internal compartment within the body to facilitate fabrication of the laminate
Data Source
AI summary
Systems and methods are provided for forming composite parts. One embodiment is an apparatus that includes a forming tool. The forming tool includes a body, which includes an exterior that defines a shape for forming a laminate that will be cured into a composite part. The body also includes elements of phase change material that provide rigidity to the body below a threshold temperature, and that exhibit a phase change above the threshold temperature causing the body to become pliable. Further, the body includes flexible material that encloses the elements of phase change material.