Sparsely Infilled Mandrel Mold Tool for Composite Ducts
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Solution Overview
Problem
Existing methods for forming composite ducts using mandrel molds are hazardous due to high heat requirements, pose ergonomic risks due to heavy weight, and generate hazardous waste, while also being costly and time-consuming.
Innovation Solution
A 3D-printed mandrel mold tool with a sparse infill structure is used to form a sacrificial mold, which is then used to mold composite ducts. The mandrel mold tool is assembled from multiple members with a sparsely filled interior that is permeable to fluids, allowing for partial curing of ceramic fill material using a hardening fluid, such as CO2 gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mandrel mold methods are used to form composite ducts, then the ducts can be manufactured with structural integrity, but the process requires high heat which creates hazardous conditions and ergonomic risks
Solution Approach 1:
The patent replaces the traditional thermal curing process with a mechanical/chemical alternative using CO2 gas infiltration. The CO2 gas reacts with the ceramic fill material at ambient or low temperatures to form calcium carbonate, curing the mandrel without requiring high heat. This substitution eliminates hazardous heat conditions while maintaining the structural integrity of the composite ducts through the same mandrel mold forming process.
2Ease of manufacture
If traditional mandrel mold methods are used, then composite ducts can be formed, but hazardous waste is generated from the process
Solution Approach 1:
The patent converts the potentially harmful CO2 gas into a beneficial curing agent. By infiltrating CO2 gas into the ceramic fill material, the gas reacts to form calcium carbonate, which strengthens and cures the mandrel. This process eliminates hazardous waste generation because the CO2 becomes part of the cured mandrel structure rather than being discarded as waste, while still enabling composite duct formation.
3Productivity
If traditional mandrel mold methods are used, then composite ducts can be manufactured, but the process is costly and time-consuming
Solution Approach 1:
The patent changes the curing parameter from high temperature to chemical reaction with CO2 gas. This parameter change dramatically reduces production time because the CO2 infiltration and reaction process occurs rapidly at ambient or low temperatures, eliminating the lengthy high-temperature curing cycle. This also reduces costs by eliminating expensive heating equipment, energy consumption, and associated safety infrastructure, while maintaining composite duct manufacturing capability.
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 the need for high heat, minimizes ergonomic risks, eliminates hazardous waste, and decreases production time and costs, while providing a safe and efficient process for forming composite ducts.
Implementation Method 1
The interior portion has a sparsely-infilled structure that is substantially permeable to fluids. The inner wall has a plurality of through-holes such that the hardening fluid, upon being introduced via the port, passes through the interior portion and the plurality of through-holes for hardening a sacrificial mold
Implementation Method 2
providing a hardening fluid into the sparsely filled interior of each of the plurality of mandrel mold tool members such that the hardening fluid permeates through the plurality of holes for partially curing the ceramic fill material to form a semi-hardened sacrificial mold
Data Source
AI summary
A mandrel mold tool for forming a mandrel includes a plurality of mandrel mold tool members that are configured for fastening together to form a mandrel mold tool having an internal compartment. The plurality of mandrel mold tool members each include an outer wall, an inner wall adjacent the outer wall, and an interior portion between the outer wall and the inner wall. The interior portion has a sparsely-infilled structure that is substantially permeable to fluids. The outer wall has a port for receiving a hardening fluid. The inner wall has a plurality of through-holes such that the hardening fluid, upon being introduced via the port, passes through the interior portion and the plurality of through-holes for hardening a sacrificial mold disposed in the internal compartment.