Two-Piece Compression Mold for Thrust Reverser Cascade Preforms

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Solution Overview

Problem

The existing methods for manufacturing thrust reverser cascades are labor-intensive and costly due to complex shapes and the need for numerous tool components, especially in compression molding processes that require multiple insert pieces for under-cut geometries, leading to high labor and quality assurance challenges.

Innovation Solution

A compression mold assembly with a first die element positioned internally and a second die element externally, defining an axis of alignment for forming a preform with curved surfaces for strong backs and vanes, and a wall assembly to create the necessary interior surfaces, allowing for the formation of preforms with under-cut geometries without requiring a large number of tool components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If multiple insert pieces are used for each cascade vane passageway to accommodate under-cut geometries, then the complex shapes of vanes and strong backs can be formed, but the number of tool parts increases significantly leading to high labor costs for tool inventory, setup, cleaning, and quality assurance

Engineering Contradiction:

Improvecomplex shapes of vanes and strong backsVSAvoidnumber of tool parts

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The mold is divided into two separable halves (first mold half and second mold half) that can be independently removed. Each half forms portions of the complex geometry, allowing under-cut features to be accommodated without requiring multiple insert pieces. The segmentation enables simple extraction of each mold half while still producing the complete complex shape.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention extracts the under-cut geometry constraints from the traditional single-piece mold approach by using two separable mold halves. This allows the mold sections to be taken out independently along a line of removal, eliminating the need for complex insert pieces while maintaining the ability to form under-cut geometries.

Inventive Principle:

Principle #2Taking out (Extraction)

2Shape

If traditional compression molding with multiple insert pieces is used, then under-cut geometries can be accommodated, but extensive labor is required for tool inventory, setup, cleaning, and quality assurance of each tooling element

Engineering Contradiction:

Improveunder-cut geometriesVSAvoidlabor for tool inventory, setup, cleaning, and quality assurance

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The mold is segmented into two halves that can be separately manufactured, stored, and maintained. This reduces tool inventory complexity compared to multiple insert pieces, and simplifies setup and cleaning procedures since each half can be independently handled.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using multiple small insert pieces to create under-cut geometries, the invention inverts the approach by using two large separable mold halves. This reversal of the traditional approach simplifies tooling management while achieving the same geometric capability.

Inventive Principle:

Principle #13The other way round (Inversion)

3Shape

If hand layup composite material fabrication is used, then complex cascade shapes can be constructed, but the process is labor intensive and results in high production cost

Engineering Contradiction:

Improvecomplex cascade shapesVSAvoidlabor intensity and production cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The invention replaces the manual mechanical hand layup process with an automated compression molding process. The two-half mold system enables thermoplastic material to be compression molded into the complex cascade shape, eliminating labor-intensive hand layup operations while maintaining the ability to produce complex geometries.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach simplifies the production of thrust reverser cascades by reducing the number of tool components needed, minimizing labor costs, and streamlining the process of forming complex geometries, thereby reducing production time and costs.

Implementation Method 1

applying a compression force on the first die element and the second die element

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

compression mold thermoplastic manufacturing processes

Methodology Applied

Scientific EffectThermoplastic manufacturing process: Melting

Data Source

PatentUS11491686B2Compression molded cascades with two piece mold

Publication Date: 2022.11.08 THE BOEING CO

AI summary

Compression mold assembly for forming a preform of a cascade includes first and second die elements and an axis of alignment. Line of removal of a formed preform is positioned perpendicular to a plane perpendicular to the axis of alignment. First die portion includes first curved surface forming interior surface of first strong back and second die portion includes first curved surface forming interior surface of a second strong back of a cell of a formed preform. Second die portion includes second curved surface forming an interior surface of a first vane on forward side of the cell of the formed preform and first die portion further includes first wall member which extends along line of removal and a second wall member which extends angularly from first wall portion forming an interior surface of a second vane positioned on an aft side of the cell.