Polymeric Aircraft Window Panel Casting Mold
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Solution Overview
Problem
The existing methods for manufacturing polymeric aircraft window panels are time-consuming and require sophisticated machinery, heavy, expensive molds, and multiple processing steps, which can result in tool marks and increased weight, affecting fuel efficiency and aesthetics.
Innovation Solution
A casting assembly using rolled, hydroformed, or stamped metal mold halves with a shaped gasket and a fluid bath, allowing for the direct casting of polymeric aircraft window panels with desired shapes and features without additional machining steps, utilizing a recirculating heater and conveyors for efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting, machining, drilling and polishing steps are used to create shaped acrylic window panels, then the desired final shape and features can be achieved, but the processing time increases and tool marks are created on the surfaces
Solution Approach 1:
The mold cavity is pre-configured with the exact final shape, edge periphery, and physical features (such as pressure equalization holes) required for the window panel. The acrylic material is then formed directly into this pre-designed cavity, eliminating the need for subsequent cutting, machining, drilling, and polishing operations.
Solution Approach 2:
The invention extracts and eliminates the unnecessary intermediate processing steps (cutting, machining, drilling, polishing) from the manufacturing workflow. Only the essential molding step remains, where the final shape is achieved directly through the mold cavity configuration.
2Manufacturing precision
If heavy, fixed-space molds are used for acrylic window panel production, then the desired shape can be achieved, but the molds are cumbersome to use and expensive to fabricate and maintain
Solution Approach 1:
The mold is divided into two separable halves (first mold half and second mold half) that can be independently handled, transported, and assembled. This segmentation makes the mold less cumbersome and easier to maintain while still achieving the desired shape accuracy through the configured cavity between the halves.
3Adaptability or versatility
If acrylic window panels are made with complex edge peripheries and surface contours, then the required functional features are achieved, but sophisticated cutting and polishing machinery with accurate control is required
Solution Approach 1:
The mold cavity is pre-configured with the exact final shape, edge periphery, and physical features (such as pressure equalization holes) required for the window panel. The acrylic material is then formed directly into this pre-designed cavity, eliminating the need for subsequent cutting, machining, drilling, and polishing operations.
4Manufacturing precision
If conventional processing steps are used to create window panels, then the desired shape can be achieved, but tool marks are created that adversely affect visible light transmittance and aesthetics
Solution Approach 1:
The invention extracts and eliminates the unnecessary intermediate processing steps (cutting, machining, drilling, polishing) from the manufacturing workflow. Only the essential molding step remains, where the final shape is achieved directly through the mold cavity configuration.
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 method reduces processing time and eliminates the need for heavy molds, minimizing tool marks and weight, while producing aircraft window panels with precise shapes and features, enhancing fuel efficiency and aesthetics.
Implementation Method 1
a recirculating heater in flow communication with the fluid bath
Implementation Method 2
a fluid bath configured to receive the mold and a recirculating heater in flow communication with the fluid bath
Data Source
Figure 1
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AI summary
A casting assembly for casting a polymeric aircraft window panel, comprising: a mold comprising a rolled, hydroformed, or stamped metal first mold half (12) and a rolled, hydroformed, or stamped metal second mold half (14); a fluid bath configured to receive the mold; and a recirculating heater in flow communication with the fluid bath as well as a casting assembly for casting a polymeric aircraft window panel, comprising: a plurality of molds, the molds comprising a rolled, hydroformed, or stamped metal first mold half and a rolled, hydroformed, or stamped metal second mold half; a heating chamber; and a plurality of conveyors extending through the heating chamber.