Vacuum Mold Tool for Automated Sealant Injection

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Solution Overview

Problem

Conventional methods for sealing structures, such as airplane wing access holes, rely on manual application of sealant, which is time-consuming and prone to excess application and trimming, leading to inefficiencies and quality issues.

Innovation Solution

A mold tool system with plural mold sub-volumes, a mold channel, sealant injection ports, vacuum application ports, and an air control system that applies vacuum to draw sealant into lower pressure zones, ensuring accurate and efficient sealant distribution and curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual application of sealant is used, then flexibility and simplicity are maintained, but time consumption and excess sealant application increase

Engineering Contradiction:

Improvesealing speedVSAvoidtime for application and trimming

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The mold is divided into multiple sub-volumes, each corresponding to a specific sealing location. This segmentation allows simultaneous filling of multiple sealing points, dramatically increasing productivity while maintaining precise control over sealant distribution at each location.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces manual mechanical application with an automated injection system that uses vacuum pressure differentials to control sealant flow. This substitution eliminates the need for manual trimming operations and significantly reduces application time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If manual application of sealant is used, then equipment complexity is minimized, but manufacturing precision and quality control deteriorate

Engineering Contradiction:

Improvesealant application precisionVSAvoidmold system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system uses vacuum pressure differentials to control sealant injection automatically. By creating a pressure difference between the injection chamber and the mold cavities, the system achieves precise sealant distribution without complex mechanical positioning mechanisms, balancing precision with acceptable complexity.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The patent controls sealant injection by changing pressure parameters - specifically by applying vacuum to create pressure differentials that drive sealant flow into the mold cavities. This parameter-based control simplifies the system compared to mechanical positioning while maintaining high precision.

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If manual application of sealant is used, then equipment cost is reduced, but material loss and rework increase

Engineering Contradiction:

Improveexcess sealant trimmingVSAvoidmold and control system complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The mold cavities are pre-configured with vacuum application ports and the injection system is pre-positioned. The vacuum field is established before injection begins, ensuring that sealant flows precisely to where it is needed without excess material requiring trimming or rework.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If vacuum is applied to mold sub-volumes, then sealant distribution precision is improved, but energy consumption increases

Engineering Contradiction:

Improvesealant placement accuracyVSAvoidvacuum application energy

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The vacuum is applied in a controlled, periodic manner - activated only during the sealant injection phase and deactivated afterward. This periodic application minimizes energy consumption while maintaining high precision during the critical injection window when sealant placement accuracy is most important.

Inventive Principle:

Principle #19Periodic action

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 reduces the time and expense of sealing by automating the sealant application process, improving quality and minimizing excess sealant usage, while allowing for precise control over sealant placement and curing.

Implementation Method 1

an air control system operably coupled to the mold sub-volumes and mold channel, the air control system configured to apply a vacuum to the mold sub-volumes via the vacuum application ports

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

drawing the sealant from a higher pressure zone into a lower pressure zone in at least one of the sub-volumes

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 3

the air control system is configured to apply a separation pressure to the sealant via the at least one separation port

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentEP3135449B1Mold, systems and methods for injection molding a sealant to an object

Publication Date: 2021.10.06 THE BOEING CO

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Figure 5A~5B

AI summary

A mold tool is provided that includes plural mold sub-volumes configured to receive a sealant, a mold channel in fluid communication with the mold sub-volumes, a sealant injection port in fluid communication with the mold channel, vacuum application ports in fluid communication with the mold sub-volumes, and an air control system. The air control system is operably coupled to the mold sub-volumes and the mold channel, and is configured to apply a vacuum to the mold sub-volumes via the vacuum application ports.