Segmented Mandrel Mold for Complex Composite Parts

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Solution Overview

Problem

Existing methods for manufacturing hollow composite parts with complex shapes, such as those in aeronautics, face challenges in efficiently forming internal cavities with concave sections wider than the part's opening, requiring resource-intensive and environmentally harmful mold dissolution or mandrel extraction methods that are not industrially viable for mass production.

Innovation Solution

A device comprising at least four molding mandrels and a locking mandrel, where the locking mandrel extends along the entire length of the molding mandrels to facilitate easy extraction by minimizing contact with the composite part and allowing radial displacement, enabling the production of hollow composite parts with complex shapes without the need for chemical tools or single-use materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If mold dissolution is used to form internal cavities, then complex shapes can be achieved, but resource consumption increases and environmental harm occurs

Engineering Contradiction:

Improvecomplex internal cavity shapeVSAvoidenvironmental harm and resource consumption

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The mold is divided into multiple separate mandrels (first mandrel, second mandrel, third mandrel) that can be individually extracted. This segmentation eliminates the need for harmful dissolution chemicals while achieving complex internal cavity shapes through the coordinated removal of discrete components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mandrels are extracted through openings in the composite part after curing. The extraction path is designed to remove each mandrel component separately through accessible openings, avoiding the need for harmful dissolution and enabling reuse of the mandrels for multiple production cycles.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If mandrels are extracted through openings in the composite part, then resource efficiency improves, but extraction is only possible for parts with specific geometries

Engineering Contradiction:

Improvemandrel extraction feasibilityVSAvoidapplicability to different part geometries

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The mold is segmented into multiple mandrels that can be extracted through different openings or paths. This allows adaptation to various part geometries, as each mandrel can be removed through the most suitable opening for its position and shape within the composite part.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mandrels are designed to be extractable through openings in the composite part by utilizing radial displacement and rotation. This multi-dimensional extraction approach enables removal of mandrels from complex geometries that would not be accessible through simple linear extraction paths.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If a solid central rod is used to tie mandrel sections together, then structural stability is achieved, but easy extraction of all mandrel parts becomes difficult

Engineering Contradiction:

Improvemandrel structural stabilityVSAvoidmandrel extraction ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Instead of a solid central rod, the mandrels are designed as separate, segmented components (first mandrel, second mandrel, third mandrel) that maintain structural stability during molding but can be individually extracted through openings in the composite part, eliminating the extraction difficulty associated with solid central rods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each mandrel component is designed to be extractable through openings in the composite part. The mandrels are removed sequentially after curing, with each component having its own extraction path, thereby achieving both structural stability during molding and ease of extraction afterward.

Inventive Principle:

Principle #2Taking out (Extraction)

4Productivity

If reusable mandrels are used for mass production, then productivity increases, but the initial device complexity increases

Engineering Contradiction:

Improvemass production capabilityVSAvoidmandrel system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The mold system is segmented into reusable mandrel components that can be individually extracted and reused for multiple production cycles. This segmentation enables mass production while keeping each individual mandrel component relatively simple in design, balancing productivity gains with manageable device complexity.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12103250B2Device comprising multiple longitudinal mandrels forming a mold for manufacturing a composite part

Publication Date: 2024.10.01 AIRBUS OPERATIONS SL

AI summary

A device and a process for manufacturing a composite part, the device comprising four molding mandrels that can be arranged in a mold arrangement in which they form a mold for the composite part, as well as a locking mandrel configured to lock the molding mandrels in the mold arrangement and to be extracted from between the molding mandrels to release the molding mandrels from their mold arrangement. The locking mandrel extends from one longitudinal end of the molding mandrels to another opposite longitudinal end of the molding mandrels.