Reconfigurable tooling using variable stiffness material

{
  "publication_number": "US8057206B1",
  "country": "US",
  "kind": "B1",
  "title": "Reconfigurable tooling using variable stiffness material",
  "abstract": "In some embodiments, reconfigurable tooling is provided having an array of actuator columns affixed to a support base. A programmable controller is configured to position the actuator columns. The reconfigurable tooling has a tooling surface which includes a variable stiffness surface capable of controllable states of stiffness, the variable stiffness surface being capable of being deformed by the actuator columns in a soften state, and rigid in a stiff state. In some embodiments, the variable stiffness surface is configurable multiple times.",
  "claims": [
    "1. Reconfigurable tooling comprising: a) an array of actuator columns affixed to a support base; b) a programmable controller configured to position the actuator columns; c) a tooling surface comprising a variable stiffness surface capable of controllable states of stiffness, the variable stiffness surface being capable of being deformed by the actuator columns in a soften state and rigid in a stiff state, and wherein the variable stiffness surface is configurable multiple times; and d) wherein the variable stiffness surface comprises a reinforced composite structure.",
    "2. The reconfigurable tooling of claim 1, wherein the variable stiffness surface is capable of comprising regions of different stiffnesses.",
    "3. The reconfigurable tooling of claim 1, wherein the variable stiffness surface comprises a grid of controllable stiffness regions.",
    "4. The reconfigurable tooling of claim 3, wherein the controllable stiffness regions are generally polygonal comprising vertices, and wherein the actuator columns are coupled to the vertices of the controllable stiffness regions.",
    "5. The reconfigurable tooling of claim 3, wherein the actuator columns are coupled to a central location of the controllable stiffness regions.",
    "6. The reconfigurable tooling of claim 1, wherein the base is deformable.",
    "7. The reconfigurable tooling of claim 1, wherein the variable stiffness surface is capable of holding a deformation imparted by the array of actuator columns without applied power.",
    "8. The reconfigurable tooling of claim 7, wherein the variable stiffness surface is capable of recovering the deformation.",
    "9. The reconfigurable tooling of claim 8, wherein the variable stiffness surface comprises shape memory polymer.",
    "10. The reconfigurable tooling of claim 7, wherein the variable stiffness surface is capable of zero power hold and of recovering the deformation.",
    "11. The reconfigurable tooling of claim 10, wherein the variable stiffness surface comprises a shape memory polymer.",
    "12. Reconfigurable tooling comprising: a) an array of actuator columns affixed to a support base; b) a means to control actuation of the actuator columns; c) a tooling surface comprising a variable stiffness surface deformable in response to the actuator columns, the variable stiffness surface being capable of holding a deformation imparted by the array of actuator columns, and wherein the variable stiffness surface is capable of recovering the deformation; and d) wherein the variable stiffness surface comprises a reinforced composite structure.",
    "13. The reconfigurable tooling of claim 12, wherein the variable stiffness surface is capable of comprising regions of different stiffnesses.",
    "14. The reconfigurable tooling of claim 12, wherein the variable stiffness surface comprises a grid of controllable stiffness regions.",
    "15. The reconfigurable tooling of claim 14, wherein the controllable stiffness regions are generally polygonal comprising vertices, and wherein the actuator columns are coupled to the vertices of the controllable stiffness regions.",
    "16. The reconfigurable tooling of claim 14, wherein the actuator columns are coupled to a central location of the controllable stiffness regions.",
    "17. The reconfigurable tooling of claim 12, wherein the base is deformable.",
    "18. The reconfigurable tooling of claim 12, wherein the variable stiffness surface comprises a shape memory polymer.",
    "19. Reconfigurable tooling comprising: a) an array of actuator columns affixed to a support base; b) a programmable controller configured to position the actuator columns; c) a tooling surface comprising a variable stiffness surface having regions of controllable stiffness, the regions being deformable in response to the actuator columns based on a selected stiffness for each of the regions; and d) wherein the variable stiffness surface comprises a reinforced composite structure.",
    "20. The reconfigurable tooling of claim 19, wherein the variable stiffness surface comprises a grid of controllable stiffness regions.",
    "21. The reconfigurable tooling of claim 20, wherein the controllable stiffness regions are generally polygonal comprising vertices, and wherein the actuator columns are coupled to the vertices of the controllable stiffness regions.",
    "22. The reconfigurable tooling of claim 20, wherein the actuator columns are coupled to a central location of the controllable stiffness regions.",
    "23. The reconfigurable tooling of claim 19, wherein the base is deformable.",
    "24. The reconfigurable tooling of claim 19, wherein the variable stiffness surface is capable of holding a deformation imparted by the array of actuator columns.",
    "25. The reconfigurable tooling of claim 24, wherein the variable stiffness surface is capable of recovering the deformation.",
    "26. The reconfigurable tooling of claim 25, wherein the variable stiffness surface comprises a shape memory polymer.",
    "27. The reconfigurable tooling of claim 24, wherein the variable stiffness surface is capable of zero power hold and of recovering the deformation.",
    "28. The reconfigurable tooling of claim 27, wherein the variable stiffness surface comprises a shape memory polymer.",
    "29. Reconfigurable tooling comprising: a) an array of actuator columns affixed to a support base; b) a means to control actuation of the actuator columns; c) a tooling surface comprising a variable stiffness surface capable of being deformed in response to the actuator columns, the variable stiffness surface being capable of providing a heterogenous stiffness; and d) wherein the variable stiffness surface comprises a reinforced composite structure.",
    "30. The reconfigurable tooling of claim 29, wherein the variable stiffness surface comprises controllable stiffness regions, and wherein the actuator columns are coupled to the controllable stiffness regions.",
    "31. The reconfigurable tooling of claim 29, wherein the base is deformable.",
    "32. The reconfigurable tooling of claim 29, wherein the variable stiffness surface is capable of holding a deformation imparted by the array of actuator columns with zero power hold, and wherein the variable stiffness surface is capable of recovering the deformation.",
    "33. The reconfigurable tooling of claim 29, wherein the variable stiffness surface comprises a shape memory polymer.",
    "34. Reconfigurable tooling comprising: a) an array of actuator columns affixed to a support base; b) a programmable controller configured to position the actuator columns; c) a tooling surface comprising a variable stiffness surface capable of controllable states of stiffness, the variable stiffness surface being capable of being deformed by the actuator columns in a soften state and rigid in a stiff state, and wherein the variable stiffness surface is configurable multiple times; and d) wherein the base is deformable.",
    "35. The reconfigurable tooling of claim 1, wherein the composite structure comprises a variable modulus material in combination with constant stiffness material segment reinforcement.",
    "36. The reconfigurable tooling of claim 12, wherein the composite structure comprises a variable modulus material in combination with constant stiffness material segment reinforcement.",
    "37. The reconfigurable tooling of claim 19, wherein the composite structure comprises a variable modulus material in combination with constant stiffness material segment reinforcement.",
    "38. The reconfigurable tooling of claim 29, wherein the composite structure comprises a variable modulus material in combination with constant stiffness material segment reinforcement."
  ],
  "description_excerpt": "A composite structure is fabricated on tooling. Generally, the tooling is made as one piece. Thus, the tooling, form, or mold, is fabricated, and then the composite structure is fabricated on top of the tooling. Tooling is typically one sided, but could be two sided.\n\nTypically, to form a composite structure, the composite material is placed on the tooling, and then pressure/vacuum is applied to hold the composite material during curing of the composite material, i.e. epoxy, thermoset composite, thermoplastic composite etc. Thus, to make a composite structure, the tooling is fabricated first, and then the composite structure. This process can be costly, especially for prototyping where one or two parts is made. What is needed is reconfigurable tooling, that can be easily and precisely configured and reconfigured to suit a particular need.\n\nIn one prior approach, reconfigurable modular tooling is proposed in U.S. Pat. No. 5,851,563 by Hoffman, herein incorporated by reference. A bed of pins is supported by a housing. Each pin is connected to a screw drive that allows the height of the entire array to be adjusted by a single motor that rasters across the unit. The work surface is defined by an array of “spring” heads which are mounted on ball joints and provide some degree of flexibility. A solid surface may be laid across these pins. In another approach, reconfigurable tooling is proposed for forming honeycomb cores in U.S. Pat. No. 6,209,380, by Papazian et al., herein incorporated by reference. In this approach, an array of rectangular cross section pins define a three dimensional work surface.",
  "cpc": [
    "B29C 33/0011",
    "B29C 33/307",
    "B29C 33/308"
  ],
  "ipc": [
    "B29C 33/22",
    "B29C 73/28"
  ],
  "assignees": [
    "HRL Laboratories LLC"
  ],
  "inventors": [
    "Geoffrey P. McKnight"
  ],
  "filing_date": "2007-09-13",
  "publication_date": "2011-11-15",
  "grant_date": "2011-11-15",
  "priority_date": "2007-09-13",
  "application_number": "US-90075907-A",
  "family_id": "44906847",
  "cited_by_count": 41,
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}