[go: up one dir, main page]

WO2012170015A1 - Procédé de formage de thermoplastique et système pour mouler des articles de formes complexes - Google Patents

Procédé de formage de thermoplastique et système pour mouler des articles de formes complexes Download PDF

Info

Publication number
WO2012170015A1
WO2012170015A1 PCT/US2011/039509 US2011039509W WO2012170015A1 WO 2012170015 A1 WO2012170015 A1 WO 2012170015A1 US 2011039509 W US2011039509 W US 2011039509W WO 2012170015 A1 WO2012170015 A1 WO 2012170015A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
thermoformable material
punch
hydraulic press
forming hydraulic
Prior art date
Application number
PCT/US2011/039509
Other languages
English (en)
Inventor
Richard L. Fingerhut
Original Assignee
International Composites Technologies, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by International Composites Technologies, Inc. filed Critical International Composites Technologies, Inc.
Priority to PCT/US2011/039509 priority Critical patent/WO2012170015A1/fr
Publication of WO2012170015A1 publication Critical patent/WO2012170015A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
    • B29C51/085—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts with at least one of the shaping surfaces being made of resilien material, e.g. rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/261—Handling means, e.g. transfer means, feeding means
    • B29C51/262—Clamping means for the sheets, e.g. clamping frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/18—Thermoforming apparatus
    • B29C51/20—Thermoforming apparatus having movable moulds or mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2081/00—Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
    • B29K2081/04—Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B29K2105/0827—Braided fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B29K2105/0845—Woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B29K2105/089—Prepregs fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2421/00—Use of unspecified rubbers as filler
    • B29K2421/006—Thermosetting elastomers

Definitions

  • the present invention is relates generally to a method and system for rapid press
  • thermoformable material forming and consolidation of a sheet of thermoformable material
  • thermoformable material for molding articles with complex shapes in a manner that
  • process involves providing a press having a fluid chamber defining a cavity for providing pressurized fluid to a surface of a blank, with a blank support for holding the blank having an opening defining a cavity, so that a punch can move through the opening into the fluid chamber.
  • Another known method provides for fluid forming of oriented thermoplastics from
  • elongated tubular blanks involves providing a longitudinally oriented tubular blank formed in a cavity to conform the tubular blank to a predetermined shape of the fluid
  • Another known technique involves using a punch made of massive rubber, and an 25 apparatus is also known for deforming a sheet of thermoplastic material by sequentially
  • the present invention provides for a method and system for rapid press forming and consolidation of a sheet of thermoformable material for molding articles with complex shapes, by utilizing uniform preheating of the sheet of thermoformable material, suspending the heated sheet of thermoformable material on a movable frame indexed to transfer the heated sheet of thermoformable material for rapid press forming and consolidation with a hydraulic punch that applies pressure uniformly in all directions, to substantially eliminate wrinkles in the formed product.
  • the present invention provides for a method and system for rapid press forming and consolidation of a sheet of thermoformable material, utilizing a part- forming hydraulic press having a rapidly movable piston with a punch formed of a deformable elastomeric material.
  • a die mold is provided in opposing relationship with the part-forming hydraulic press configured to receive the punch of the part-forming hydraulic press, and the part-forming hydraulic press and the die mold define a molding and consolidation position between the part-forming hydraulic press and the die mold.
  • a preheating and preconsolidation station is also provided for heating the sheet of thermoformable material.
  • a track extends between the preheating and preconsolidation station and the molding and consolidation position, and a movable frame for holding the sheet of thermoformable material is mounted on the track. The movable frame is indexed to be movable along the track between the preheating and preconsolidation station and the molding and consolidation position.
  • the movable frame includes an inner plate suspended from the interior channel, and the inner plate has an aperture configured to receive at least a portion of a sheet of thermoformable molding composite material.
  • the peripheral edges of the sheet of thermoformable material are removably secured within an interior channel of the movable frame, such as by a retaining strip secured within the interior channel, for example, so as to suspend the sheet of thermoformable material over aperture of the inner plate.
  • thermoformable material is heated on the movable frame at the preheating and preconsolidation station, and is then transferred, suspended on the movable frame, to the molding and consolidation position, where the heated sheet of thermoformable material is rapidly punched with the punch of the part-forming hydraulic press, in as little a approximately 3 microseconds, for example, to form a consolidated, molded sheet of thermoformable material.
  • the step of rapidly punching the heated sheet of thermoformable material with the punch of the part- forming hydraulic press comprises applying pressure to the heated sheet of
  • thermoformable material uniformly in all directions, to substantially eliminate wrinkles in the formed product.
  • the consolidated, molded sheet of thermoformable material is then released and allowed to cool.
  • the sheet of thermoformable material can be a fiber reinforced thermoplastic, a fiber reinforced thermosetting plastic, or a metal matrix, such as aluminum or silicone carbide-reinforced aluminum, for example, APC-2 PEEK (polyetheretherketone), PEI (polyethylene imine), PPS (polypropylene sulfide), PAS-2 (poly(phenylene sulfide sulfone)), a thermoplastic resin, acrylic prepreg, epoxy and polyester prepreg, nylon, polypropylene, SiCp (silicon carbide particulate )/aluminum metal matrix composites (MMC), polyethylene fiber, thermoplastic aramid, a butyl-backed woven polymer reinforcing fabric, a bidirectional fabric, a braided-slit tape, an interlaced fabric, a powdered towpreg, woven commingled fabric, or a thermoset prepreg, for example.
  • APC-2 PEEK polyetheretherketone
  • PEI
  • the sheet of thermoformable material can be covered with a film such as nylon, silicone, polyurethane, Kapton, Upilex, polyethylene, aluminum, or combinations thereof, and the film may have a thickness of about 0.5 mil to about 0.050 inch thick, for example.
  • the step of heating the sheet of thermoformable material can be accomplished in an infrared oven, in a convection heater, or using heated platens, for example.
  • the punch can be formed of an elastomeric material such as rubber or polyurethane elastomer, for example.
  • the punch can include an outer casing defining an interior chamber mounted to the rapidly movable piston of the part-forming hydraulic press.
  • the outer casing can be formed by a plurality of layers of elastomeric material, such as a tougher outer layer and a softer inner layer, or a softer outer layer and a tougher inner layer, for example.
  • the punch is a hydrostatic punch that applies pressure uniformly in all directions, to substantially eliminate wrinkles in the formed product.
  • Figure 1 is a schematic diagram of the system for rapid press forming and consolidation of a sheet of thermoformable material according to the present invention.
  • Fig. 2 is a flow chart of the steps of the method for rapid press forming and consolidation of a sheet of thermoformable material according to the present invention.
  • Fig. 3 is a schematic diagram of the part-forming hydraulic press of the system of
  • Fig. 4 is a cross-sectional view of a punch of the part-forming hydraulic press of
  • Fig. 5 is a cross-sectional view of a variation of the punch of the part-forming hydraulic press of Fig. 3.
  • Fig. 6 is a schematic diagram of a radiant infrared (IR) heater or oven of the system of Fig. 1.
  • IR radiant infrared
  • Fig. 7 is a schematic diagram of a convection type heater or oven for the system of
  • Fig. 1 is a schematic diagram of a platen type heater for the system of Fig. 1.
  • Fig. 9 is a top plan view of the movable frame of the system of Fig. 1.
  • Fig. 10A is an enlarged view of a portion of the movable frame of Fig. 9.
  • Fig. 10B is a partial sectional view of a portion of the movable frame taken along line 10B-10B of Fig. 9.
  • Fig. 11 is a schematic diagram of the system of Fig. 1 illustrating a first indexed position of the movable frame at the preheating and preconsolidation station.
  • Fig. 12 is a schematic diagram of the system of Fig. 1 illustrating a second indexed position of the movable frame at the molding and consolidation station.
  • the present invention provides for a system 10 for rapid press forming and consolidation of a sheet of thermoformable material 12 which is removably mounted on a form or frame 14, such as a square or rectangular form or frame, for example.
  • the sheet of thermoformable material can be a fiber reinforced thermoplastic, a fiber reinforced thermosetting plastic, or a metal matrix, such as aluminum or silicone carbide-reinforced aluminum, for example, APC-2 PEEK (polyehteretherketone), PEI (polyethylene imine), PPS (polypropylene sulfide), PAS-2 (poly(phenylene sulfide sulfone)), a thermoplastic resin, acrylic prepreg, epoxy and polyester prepreg, nylon, polypropylene, SiCp (silicon carbide particulate)/aluminum metal matrix composites (MMC), polyethylene fiber, thermoplastic aramid, a butyl-backed woven polymer reinforcing fabric, a bidirectional fabric, a braided-slit tape, an interlaced fabric, a powdered towpreg, woven commingled fabric, or a thermoset prepreg, for example.
  • APC-2 PEEK polyehteretherketone
  • the sheet of thermoformable material optionally also may be covered with a film such as nylon, silicone, polyurethane, Kapton, Upilex, polyethylene, aluminum, or combinations thereof, and the film may have a thickness of about 0.5 mil to about 0.050 inch thick, for example.
  • the membrane or film acts as a release film and carrier, and thermally insulates and supports the molding composite.
  • the form or frame with the sheet of thermoformable material removably mounted on it is rapidly movable on a track 16 that preferably extends between an indexed station in a heater or oven 18 and an indexed station in a part-forming hydraulic press 20, as is illustrated in Figs. 1, 11 and 12. Referring to Fig.
  • the method of the invention for rapid press forming and consolidation of a sheet of thermoformable material involves removably securing the peripheral edges of a sheet of thermoformable material within an interior channel of a movable frame so as to suspend the sheet of thermoformable material over an aperture of an inner plate of the frame, as is shown in step 22.
  • the sheet of thermoformable material removably secured and suspended on the movable frame is transferred on a track to a preheating and preconsolidation station, and is heated in step 26 at the preheating and preconsolidation station to provide a heated sheet of thermoformable material suspended on said movable frame, typically in approximately 2.5 minutes.
  • the heated sheet of thermoformable material is then rapidly transferred in step 28, suspended on the movable frame, to be placed in the molding and consolidation station between the punch of the part- forming hydraulic press and the die mold in step 30.
  • the heated sheet of thermoformable material is then rapidly punched in step 32 with the punch of the part-forming hydraulic press, by rapidly moving the punch of the part-forming hydraulic press into molding engagement with the die mold, with the heated sheet of thermoformable material therebetween, in as little as approximately 3 microseconds, for example, to form a consolidated, molded sheet of thermoformable material.
  • the punch of the part-forming hydraulic press preferably applies pressure to the heated sheet of thermoformable material uniformly in all directions, to substantially eliminate wrinkles in the formed product.
  • the consolidated, molded sheet of thermoformable material is released from between the punch of the part-forming hydraulic press and the die mold, and allowed to cool. In total, the transfer, forming and cool down operation also typically takes approximately 2.5 minutes.
  • the part-forming hydraulic press preferably includes a rapidly movable piston 36 including a punch 38 preferably formed of a deformable elastomeric material affixed at a first end 40 of the movable piston, and a die mold 42 disposed in opposing relationship with the part-forming hydraulic press and configured to receive the punch of the part-forming hydraulic press.
  • the die mold is typically a concave type of mold that can be formed of an elastomeric material, and can have an interior surface coated with or formed of silicone.
  • the punch is typically mostly solid, and can have a metal support, or fluid inside.
  • the punch preferably includes an outer casing 44 formed of an elastomeric material such as rubber or polyurethane elastomer that can be about 3 inches thick, for example.
  • the outer casing of the punch can deform during the thermoforming process in response to stresses in the thermoplastic sheet material to substantially eliminate wrinkles in the finished product.
  • the outer casing of the punch preferably defines an interior chamber 46, that is typically hollow, and may be filled with air or a material such as a fluid or metal, for example, and is mounted to a mounting portion 48 of the piston of the part-forming hydraulic press, which may include an interior metal frame support structure 49 which can be bolted to the mounting portion of the press, and the elastomeric punch head outer casing may be formed over the interior metal frame support structure.
  • the outer casing of the punch can be formed by a plurality of layers of elastomeric material, such as a tougher outer layer 50a and a softer inner layer 50b, as shown in Fig. 4, although in a variation the outer casing also could alternatively be formed by a plurality of layers of elastomeric material, such as or a softer outer layer 52a and a tougher inner layer 52b, as shown in Fig. 5, for example.
  • the punch is a hydrostatic type of punch that applies pressure uniformly in all directions, to substantially eliminate wrinkles in the formed product.
  • the elastomeric punch is formed as an exterior convex mold, is durable, and will deform in response to sideward pressures as well as downward or reactive pressures due to forces exerted by the punch, which typically moves very fast, and typically completes a punch on the thermoplastic material in approximately 3 microseconds, for example.
  • the preheating and preconsolidation station can include an infrared oven 58, such as a radiant infrared (IR) heater or oven, with electric heating coils 59, for example.
  • IR radiant infrared
  • Other types of heaters or ovens may also be suitable, such as a convection heater 60 illustrated in Fig. 7, typically providing a flow of heated air heated such as by a gas burner 61, for example, or a platen type heater illustrated in Fig.
  • heated platens 62a, 62b typically of type formed of large steel plates 64 and typically containing electrical cartridge heaters 66, and applied with pressure against the material to be heated, for example.
  • the heater or oven provides for single-step heating and consolidation in 2 1 ⁇ 2 to 5 minutes, with heating temperature uniformity to within approximately ⁇ 2°C of a desired molding and
  • the movable frame mounted on the track preferably includes an interior channel 68 formed around the perimeter 70 of the frame.
  • An inner plate 72 typically having a rectangular or square configuration, includes a centrally located aperture 74, typically of an oval or circular shape, for example, or as desired for the complex shape to be formed, and is suspended from the interior channel by means 76 for suspending the inner plate, which can be a plurality of resilient devices or elastic members, such as heat resistant elastomeric members or tension springs, for example, connected between the exterior corners 78 of the inner plate and interior corners 80 of the perimeter of the frame.
  • the aperture of the inner plate is configured to receive at least a portion of the sheet of thermoformable material when the sheet of thermoformable material is punched by the punch of the part-forming hydraulic press.
  • a retaining strip 82 typically formed of an elongated heat resistant elastomeric material, is preferably secured within the interior channel, and is configured to removably secure the peripheral edges 84 of the sheet of thermoformable material within the interior channel over the inner plate.
  • the movable frame helps to stabilize the composite sheet material against forming wrinkles for articles being formed with severe contours. Referring to Figs.
  • the movable frame is indexed on the track to be movable between a first indexed position 86 at the preheating and preconsolidation station and a second indexed position 88 at the molding and consolidation station between the part-forming hydraulic press and the die mold.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

Le procédé et le système utilisés pour le formage rapide à la presse et consolidation d'une feuille de matière thermoformable assurent le moulage d'articles de formes complexes. La feuille de matière thermoformable est suspendue à un cadre mobile et est transférée sur une voie à une station de préchauffage et de préconsolidation, où elle est chauffée et rapidement transférée dans un état suspendu au cadre mobile, par l'intermédiaire de la voie, jusqu'à une station de moulage et de consolidation assurant le formage rapide à la presse et la consolidation au moyen d'un poinçon hydraulique qui applique une pression uniformément dans toutes les directions pour éliminer sensiblement les plis dans le produit formé.
PCT/US2011/039509 2011-06-07 2011-06-07 Procédé de formage de thermoplastique et système pour mouler des articles de formes complexes WO2012170015A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2011/039509 WO2012170015A1 (fr) 2011-06-07 2011-06-07 Procédé de formage de thermoplastique et système pour mouler des articles de formes complexes

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2011/039509 WO2012170015A1 (fr) 2011-06-07 2011-06-07 Procédé de formage de thermoplastique et système pour mouler des articles de formes complexes

Publications (1)

Publication Number Publication Date
WO2012170015A1 true WO2012170015A1 (fr) 2012-12-13

Family

ID=44627868

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2011/039509 WO2012170015A1 (fr) 2011-06-07 2011-06-07 Procédé de formage de thermoplastique et système pour mouler des articles de formes complexes

Country Status (1)

Country Link
WO (1) WO2012170015A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022013196A1 (fr) * 2020-07-16 2022-01-20 Essilor International Machine et procédé d'obtention d'une surface incurvée pour une structure de film
CN114606695A (zh) * 2022-03-18 2022-06-10 惠州市众畅汽车部件有限公司 一种内衬无纺布热成型方法

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004022300A2 (fr) * 2002-09-04 2004-03-18 Alan Jordan Procede et appareil de thermoformage sans dechets
US20070296117A1 (en) * 2004-06-18 2007-12-27 Taeye Arno D Process And Apparatus For Making A Plastic Component From Self-Reinforced Thermo-Plastic Material And Plastic Component Produced
US20110147995A1 (en) * 2009-12-22 2011-06-23 International Composites Technologies, Inc. Thermoplastics forming process for molding articles with complex shapes

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004022300A2 (fr) * 2002-09-04 2004-03-18 Alan Jordan Procede et appareil de thermoformage sans dechets
US20070296117A1 (en) * 2004-06-18 2007-12-27 Taeye Arno D Process And Apparatus For Making A Plastic Component From Self-Reinforced Thermo-Plastic Material And Plastic Component Produced
US20110147995A1 (en) * 2009-12-22 2011-06-23 International Composites Technologies, Inc. Thermoplastics forming process for molding articles with complex shapes

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022013196A1 (fr) * 2020-07-16 2022-01-20 Essilor International Machine et procédé d'obtention d'une surface incurvée pour une structure de film
US12290998B2 (en) 2020-07-16 2025-05-06 Essilor International Machine and method for obtaining a curved surface for a film structure
CN114606695A (zh) * 2022-03-18 2022-06-10 惠州市众畅汽车部件有限公司 一种内衬无纺布热成型方法

Similar Documents

Publication Publication Date Title
US8309009B2 (en) Thermoplastics forming process for molding articles with complex shapes
US8771823B2 (en) Thermoplastic part, tool and method for the manufacturing thereof
EP2954994B1 (fr) Systèmes et procédés permettant de définir un profil de surface d'une charge en couches de matériau
EP2915645B1 (fr) Procédé pour fabriquer une préforme et procédé pour fabriquer un article moulé en résine renforcé par des fibres
CN106239878B (zh) 树脂成型体的制造方法及冲压成型装置
JP6109196B2 (ja) 繊維強化された成形部材の製造中に繊維スクリムから三次元のプリフォームを製造する方法並びに装置
US20180281319A1 (en) Method for producing a component from a fiber-composite material
US12172396B2 (en) Systems and methods for manufacturing large contoured parts from thermoplastic laminate sheets
US20190016039A1 (en) Method and press for making a press from fiber composite
CN104053528A (zh) 用于在纤维加强模制件的生产过程中由纤维织物叠层生产三维预制件的方法及装置
EP1332029A1 (fr) Procede et appareil de preparation d'un article moule
CA2916215A1 (fr) Outil de formage et methode de formage d'un produit semi-fini comportant des fibres de renfort et appareil de formage
KR20220092400A (ko) 탄소섬유복합재 부품의 제조방법 및 제조장치
CA2593519A1 (fr) Piece thermoplastique inedite, outil et procede de fabrication
WO2012170015A1 (fr) Procédé de formage de thermoplastique et système pour mouler des articles de formes complexes
JP2022516512A (ja) 複合材料の機械的成形
JP2016179598A (ja) 繊維強化熱可塑性樹脂からなる成形体の成形方法
JP7310027B2 (ja) 賦形装置および賦形方法
KR20100065498A (ko) 곡면을 구비한 복합재료의 제조방법
JP2019025679A (ja) 金属−繊維強化樹脂複合成型体の製造方法
JPWO2021095626A5 (fr)
AU2018100761A4 (en) Composite shell and apparatus and method for forming same
US20250010537A1 (en) Additively reinforced thermoforming
KR102292292B1 (ko) 소재 성형 장치 및 소재 성형 방법
US11001015B2 (en) Diaphragm tool for forming reinforcement fiber tiers into preformed t-shaped profiles

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 11729499

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 11729499

Country of ref document: EP

Kind code of ref document: A1