Method for fabricating tapered thermoplastic composite parts
First Claim
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1. Consolidation tooling for use in a continuous compression molding machine to fabricate a fiber reinforced thermoplastic part having a varying height, comprising:
- a first tool die and a second tool die, the first tool die and the second tool die each adapted to mold a multi-ply stack of thermoplastic prepreg into a part; and
at least a first tooling sleeve movable between the first tool die and the second tool die, the first tooling sleeve having at least a first tapered portion engageable with the multi-ply stack of thermoplastic prepreg,wherein the first tool die is tapered along its length substantially complementary to the first tapered portion of the first tooling sleeve,a third tool die and a fourth tool die, the third tool die and the fourth tool die each adapted to compress and mold the multi-ply stack of thermoplastic prepreg into a web region of the part,a first tooling member attached to the first tool die and a second tooling member attached to the second tool die, wherein the first tooling member applies a first compressive force directly to the multi-ply stack of thermoplastic prepreg and the second tooling member applies a second compressive force directly to the multi-ply stack of thermoplastic prepreg.
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Abstract
Consolidation tooling is used in a continuous compression molding machine to produce a fiber reinforced thermoplastic part having a varying height. The tooling includes first and second tool dies adapted to compress and form a multi-ply stack of thermoplastic prepreg into a part, and at least a first tooling sleeve movable through the first and second tool dies. The tooling sleeve has at least a first tapered portion engageable with the multi-ply stack.
103 Citations
14 Claims
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1. Consolidation tooling for use in a continuous compression molding machine to fabricate a fiber reinforced thermoplastic part having a varying height, comprising:
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a first tool die and a second tool die, the first tool die and the second tool die each adapted to mold a multi-ply stack of thermoplastic prepreg into a part; and at least a first tooling sleeve movable between the first tool die and the second tool die, the first tooling sleeve having at least a first tapered portion engageable with the multi-ply stack of thermoplastic prepreg, wherein the first tool die is tapered along its length substantially complementary to the first tapered portion of the first tooling sleeve, a third tool die and a fourth tool die, the third tool die and the fourth tool die each adapted to compress and mold the multi-ply stack of thermoplastic prepreg into a web region of the part, a first tooling member attached to the first tool die and a second tooling member attached to the second tool die, wherein the first tooling member applies a first compressive force directly to the multi-ply stack of thermoplastic prepreg and the second tooling member applies a second compressive force directly to the multi-ply stack of thermoplastic prepreg. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. Consolidation tooling for use in a continuous compression molding machine to fabricate a fiber reinforced thermoplastic part having a varying height, comprising:
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a first tool die and a second tool die, the first tool die and the second tool die each adapted to mold a multi-ply stack of thermoplastic prepreg into a part, wherein the first tool die and the second tool die are horizontally opposed to each other; a third tool die and a fourth tool die, wherein the third tool die and the fourth tool die are each adapted to apply a compressive force in a vertical direction to the multi-ply stack of thermoplastic prepreg and mold the multi-ply stack of thermoplastic prepreg into a web region of the part, wherein the third tool die and the fourth tool die are vertically opposed to each other; a first tooling member attached to the first tool die, wherein the first tooling member extends vertically along an inwardly facing surface of the first tool die; wherein the inwardly facing surface of the first tool die is tapered along its length and the first tooling member applies a first compressive force, in a horizontal direction directly to the multi-ply stack of thermoplastic prepreg; a second tooling member attached to the second tool die, wherein the second tooling member extends vertically along an inwardly facing surface of the second tool die; wherein the inwardly facing surface of the second tool die is tapered along its length and the second tooling member applies a second compressive force, in the horizontal direction directly to the multi-ply stack of thermoplastic prepreg; a first tooling sleeve movable between the first tool die and the second tool die, the first tooling sleeve having at least a first tapered portion and at least a second tapered portion; and a second tooling sleeve movable between the first tool die and the second tool die, the second tooling sleeve having at least a first tapered portion and at least a second tapered portion. - View Dependent Claims (14)
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Specification