Segmented Moulding Tools for Composite Manufacturing Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing processes for manufacturing large composite parts are inefficient and costly, requiring complex setups and lengthy cycles for moulding and curing.
Innovation Solution
A method involving the use of two mould tools, where one tool is attached to a press and the other is loaded with reinforcement material at a separate workstation, then brought into mating arrangement to define a mould cavity, allowing for efficient injection and curing of matrix material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the traditional moulding process is used where all mould parts are assembled around reinforcing fibres before pressing, then the mould cavity is properly formed, but the manufacturing time and process complexity increase significantly
Solution Approach 1:
The mould tool is divided into two separate mould tools, each performing a specific function. The first mould tool defines part of the mould cavity and is attached to the press, while the second mould tool with demountable mould bodies loads reinforcement material and defines the remaining part of the mould cavity. This segmentation allows independent preparation and reduces assembly time.
Solution Approach 2:
The second mould tool is pre-loaded with reinforcement material at a separate workstation before being brought to the press. This preliminary action of loading reinforcement material outside the press eliminates the need to disassemble and reassemble mould parts during the pressing operation, significantly reducing manufacturing time.
2Manufacturing precision
If all mould parts are assembled around reinforcing fibres before pressing, then the reinforcement material is properly positioned, but the device complexity and setup requirements increase
Solution Approach 1:
The moulding system is segmented into two separate mould tools with distinct functions. The first mould tool focuses on defining the mould cavity and is integrated with the press, while the second mould tool handles reinforcement material loading with demountable mould bodies. This segmentation simplifies each tool's design and reduces overall assembly complexity.
Solution Approach 2:
The demountable mould bodies on the second mould tool act as intermediaries that can be easily attached and detached. These intermediary components facilitate the loading of reinforcement material and then can be removed or kept separate, reducing the complexity of the overall mould assembly compared to a fully integrated single mould tool.
3Ease of manufacture
If the moulding process is performed in a single integrated operation, then the process is simple, but the energy consumption and time required for curing increase
Solution Approach 1:
The first mould tool remains attached to the press during the curing operation, allowing the press to maintain temperature and pressure continuously. This eliminates the need to reposition or reheat the entire mould assembly after moulding, reducing energy consumption for both moulding and curing operations.
Solution Approach 2:
The moulding and curing operations are merged into a single continuous process. The first mould tool serves dual purposes: defining the mould cavity during moulding and maintaining the curing environment. This merging of functions reduces total energy consumption by eliminating redundant heating and positioning steps.
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 enhances the efficiency and cost-effectiveness of composite part manufacturing by reducing the time and energy required for moulding and curing, while allowing for the production of complex and large-dimension components.
Implementation Method 1
The press has a floor 8 and compression heads 9, 10, 11. The compression heads are mounted on hydraulic rams 12. One ram can force head 9 into opposition with floor 8. The other rams can force heads 10, 11 into opposition with each other.
Implementation Method 2
The step of setting in shape the reinforcement material may comprise solidifying the matrix material, e.g. by curing it.
Data Source
AI summary
A method for forming a composite component, the method comprising: providing a first mould tool and a second mould tool, the first and second mould tools being configured so as to be capable of defining at least part of a mould cavity between them, and the second mould tool having a moulding surface defined by at least two demountable mould bodies; attaching the first mould tool to a press at a first workstation; subsequently, at a second workstation spaced from the first workstation, loading at least part of the second mould tool with reinforcement material whilst the first mould tool remains attached to the press at the first workstation; moving the second mould tool to the press at the first workstation in such a position as to confront the first mould tool; causing the press to effect relative movement of the first and second tools to bring the first and second tools into mating arrangement so as to define a mould cavity therebetween; and setting in shape the reinforcement material located in the mould cavity.