Method and material efficient tooling for continuous compression molding

• US 20080185756A1
• Filed: 02/03/2007
• Published: 08/07/2008
• Est. Priority Date: 02/03/2007
• Status: Active Grant

• Current Assignee: M/C 1640-2101, The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Wilkerson, Randall D., Rubin, Alexander M., Fox, James R.
• Granted Patent: US 8,491,745 B2
• Time in Patent Office: Days
• US Class Current: 264/297.4
• CPC Class Codes: B29C 43/14 in several steps
• CPC Class Codes: B29C 43/22 of articles of indefinite length
• CPC Class Codes: B29C 43/228 using endless belts feeding the material between non-rotating pressure members, e.g. vibrating pressure members
• CPC Class Codes: B29C 70/42 for producing articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 70/526 Pultrusion dies, e.g. dies with moving or rotating parts B29C70/523 takes precedence
• CPC Class Codes: B29C 70/54 Component parts, details or accessories; Auxiliary operations , e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
• CPC Class Codes: B29D 7/01 Films or sheets
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: Y10T 156/101 Prior to or during assembly with additional lamina
• CPC Class Codes: Y10T 156/1737 Discontinuous, spaced area, and/or patterned pressing

Abstract

Thermoplastic laminates are fabricated in a continuous compression molding production line. A lay-up of laminate plies is placed in a recess on a carrying tool, and the tool is moved through successive forming operations on the line, including preforming and consolidation operations. The tool is separated from the fully formed part at the end of the line and may be reused. Use of the carrying tool reduces material scrap.

Claims

1. Tooling used in a continuous process for forming laminated thermoplastic parts using a lay-up of laminate plies, comprising:

a rigid body having first and second ends,

the body including a recessed area,

the first and second ends of the rigid body extending beyond the recessed area.

2. The tooling of claim 1, wherein the recess defines first and second shoulders in the body for respectively engaging an end of the part.

3. The tooling of claim 1, wherein the recess has a depth substantially equal to a thickness of the part.

4. The tooling of claim 1, wherein the recess has a depth such that outer surfaces of the tooling are substantially coplanar with outer surfaces of the part.

5. The tooling of claim 1, wherein the body has a cross sectional shape generally matching the cross sectional shape of the consolidated part.

6. The tooling of claim 1, wherein the body is elongate and the recess is formed in the body between the first and second ends of the body.

7. The tooling of claim 1, wherein the first and second ends of the body have an outer surface extending substantially coplanar with an outer surface of the part.

8. The tooling of claim 1, wherein the recessed area has the general shape of a part and the part is carried in the recessed area.

9. The tooling of claim 1, wherein the recessed area has a depth that varies in at least one direction across the recessed area.

10. The tooling of claim 1, wherein the body includes tooling features within the recessed area for forming shapes in a part.

11. Tooling for carrying a lay-up of laminate plies though a continuous compression molding line used to produce a part, comprising:

an elongate body having opposite first and second ends,

the body having at least one recess,

the first and second ends of the rigid body extending respectively beyond opposite ends of the at least one recess lay-up and having outside surfaces forming an extension of the profile of the part when the lay-up is compressed into the shape of the part.

12. The tooling of claim 11, wherein the at least one recess has the general shape of the part and the lay-up is received within the at least one recess.

13. The tooling of claim 11, wherein the recess has a depth substantially equal to a thickness of the part.

14. The tooling of claim 11, wherein the outside surfaces of the body are substantially coplanar with exterior surfaces of the compressed part.

15. The tooling of claim 11, wherein the recess defines first and second shoulders in the body, and the first and second shoulders engage opposite ends of the part.

16. The tooling of claim 11, wherein body has a cross sectional shape generally matching the cross sectional shape of the part.

17. The tooling of claim 11, wherein the first end of the body extends beyond the recess a length sufficient such that at least portions of the first end of the body pass through the molding line before the lay-up enters the molding line.

18. The tooling of claim 11, wherein the second end of the body extends beyond the recess a length sufficient such that at least portions of the second end of the body pass remain in the molding line after the lay-up has passed through the molding line.

19. The tooling of claim 11, wherein the at least one recess has a non-uniform depth.

20. The tooling of claim 11, wherein the body includes tooling features within the at least one recess for forming shapes in the part.

21. A method of fabricating a thermoplastic laminate part using a continuous compression molding line, comprising the steps of:

(A) placing a laminate lay-up in a recess formed in a tool; and

,

(B) moving the tool through the molding line.

22. The method of claim 21, wherein step (B) is performed by pulling the tool through the molding line.

23. The method of claim 21, further comprising the steps of:

(C) passing the tool through a preforming operation;

(D) shaping the lay-up into a preformed part as the tool passes through the preforming operation;

(E) passing the tool through a consolidation operation;

(F) consolidating the preformed part as the tool passes through the consolidation operation; and

,

(G) removing the part from the tool after step (F) has been completed.

24. A thermoplastic laminate part fabricated by the method of claim 21.

25. A method of fabricating a composite material part, comprising the steps of:

(A) supporting a lay-up of composite material on a tool;

(B) moving a portion of the tool through a continuous compression molding line before the lay-up enters the molding line;

(C) shaping the lay-up into a preformed part as step (B) is performed;

(D) consolidating the preformed part as step (B) is performed; and

,

(E) removing the part from the tool after step (D) has been completed.

26. The method of claim 25, wherein step (A) includes placing the lay-up in a recess of the tool.

27. A composite material part fabricated by the method of claim 25.