Segmented Composite Duct Molding Tool for Uniform Curing
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Solution Overview
Problem
Existing tooling for manufacturing aircraft turbomachine ducts in composite materials faces issues with large size, high mass, thermal inhomogeneity, poor mechanical properties due to inhomogeneous polymerization, difficulty in handling, inability to apply uniform pressure, and aerodynamic incompatibility, leading to defects and increased production costs.
Innovation Solution
A novel molding tool comprising a base and a body with removable parts, allowing fiber sheets to be draped over a rigid structure, enabling better thermal homogeneity, reduced mass, and simultaneous production of multiple ducts, with a remote heating system and vacuum application for improved pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a steel mold with integrated heating system is used, then the mold can heat the preform during polymerization, but the mold becomes very large and heavy, making it difficult to handle
Solution Approach 1:
The heating system is extracted from the mold structure and relocated to an external position. The patent places heating elements outside the mold cavity, allowing the mold itself to be lightweight while still providing the necessary thermal energy for polymerization through external heating means.
Solution Approach 2:
The mold is divided into multiple separable parts rather than a single integrated structure. This segmentation allows the mold components to be smaller, lighter, and easier to handle individually, while collectively forming the complete molding system when assembled.
2Strength
If a steel mold with integrated heating system is used, then the mold can maintain structure during heating, but thermal inhomogeneity occurs in the resin during polymerization
Solution Approach 1:
A flexible membrane is introduced as an intermediary layer between the preform and the rigid mold structure. This membrane allows for more uniform heat distribution across the preform surface while the rigid mold maintains its structural integrity, resolving the conflict between structural stability and thermal homogeneity.
Solution Approach 2:
The mold system incorporates flexible or adjustable elements that can adapt during the heating process. The flexible membrane dynamically conforms to the preform shape and facilitates more uniform thermal contact, while the rigid mold provides stable structural support.
3Ease of manufacture
If a flexible membrane is used as tooling, then the preform can be molded, but insufficient pressure is applied leading to resin pockets without fiber reinforcement
Solution Approach 1:
The tooling system is segmented into multiple discrete elements rather than a single flexible membrane. This segmentation allows individual pressure points to be applied at strategic locations, ensuring uniform pressure distribution and preventing resin pockets while maintaining ease of manufacturing.
Solution Approach 2:
The flexible membrane mechanical system is replaced or supplemented with a rigid mold structure that provides more reliable and uniform pressure application. The rigid structure maintains consistent contact pressure across the preform surface, eliminating the pressure distribution problems associated with flexible membranes.
4Ease of manufacture
If a flexible membrane is used as tooling, then the preform can be molded, but the internal surface lacks aerodynamic compatibility due to surface undulations
Solution Approach 1:
The flexible membrane tooling is replaced with a rigid mold structure that provides a precise, stable surface for molding. The rigid mold maintains exact geometric fidelity throughout the molding process, producing surfaces with the required aerodynamic smoothness and eliminating undulations that occur with flexible membranes.
Solution Approach 2:
The rigid mold is divided into multiple precision-machined segments that can be assembled to form the complete tooling. This segmentation allows for precise manufacturing of each segment with tight tolerances, ensuring that the assembled mold provides a uniformly smooth surface for aerodynamic compatibility.
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 facilitates handling, ensures thermal homogeneity, improves mechanical properties, reduces manufacturing costs, and enhances aerodynamic compatibility, allowing for precise control of final geometry and simultaneous production of multiple ducts.
Implementation Method 1
with a vacuum maintained at the preform level
Implementation Method 2
polymerizable resin, intended to impregnate and stiffen the preform, is injected into it
Implementation Method 3
the tooling continues to heat to complete the resin polymerization
Implementation Method 4
complete the resin polymerization
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a tool (30) for moulding a duct for an aircraft turbine engine, the duct being made of a fibre-based composite material and comprising a curved tubular portion, one end of which is connected to a peripheral flange, this tool (30) comprising: - a base (40); - a generally elongate and curved body (50), this body (50) being formed by an assembly of first parts (52) which are fitted tightly together and which include a first central release key (53) which extends from one end of the body (50) to the other and which is configured to be removed first upon release of the body (50). The invention also relates to a method for manufacturing a duct for an aircraft turbine engine using a tool (30) as previously described.