Apparatus for diaphragm forming

• US 5,648,109 A
• Filed: 05/03/1995
• Issued: 07/15/1997
• Est. Priority Date: 05/03/1995
• Status: Expired due to Fees

• Current Assignee: Massachusetts Institute of Technology
• Original Assignee: Massachusetts Institute of Technology
• Inventors: Dillon, Gregory P., Li, Haorong, Gutowski, Timothy G., Chey, Sukyoung
• Primary Examiner(s): DAVIS, ROBERT B
• Application Number:
  US08/433,125
• Time in Patent Office: 804 Days
• Field of Search: 425/389, 425/390, 425/504, 425/DIG. 44, 264/314, 156/212, 156/223, 156/382, 156/475
• US Class Current: 425/504
• CPC Class Codes: B29C 51/085 with at least one of the shaping surfaces being made of resilien material, e.g. rubber
• CPC Class Codes: B29C 70/44 using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
• CPC Class Codes: B30B 5/02 wherein the pressing means is in the form of a flexible element, e.g. diaphragm, urged by fluid pressure
• CPC Class Codes: Y10S 425/044 Rubber mold
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/1046 Bending of one lamina only

Abstract

Apparatus and methods for forming an article of advanced composites on a tool forming surface from a preform are disclosed. Apparatus includes, according a preferred embodiment, a tool forming surface, a first diaphragm for urging a preform into conforming contact with the tool forming surface, and a second diaphragm for supporting a side of the preform opposite the side engaged by the first diaphragm during forming. The second diaphragm does not extend completely between the preform and the tool forming surface. The apparatus is arranged with a first diaphragm mountable on the apparatus and conformable to a preform to be formed and a second diaphragm mounted on the apparatus and conformable to a portion of the preform simultaneously with the first diaphragm. A forming tool is provided, including a tool forming surface positionable for receiving the preform between the first diaphragm and the second diaphragm when the first and second diaphragms are mounted on the apparatus.

Claims

1. Apparatus for forming an article on a surface of a forming tool, comprising:

a first diaphragm mountable on the apparatus and conformable to a preform to be formed;

a second diaphragm mounted on the apparatus and conformable to a portion of the preform simultaneously with the first diaphragm;

a forming tool having a tool forming surface positionable for receiving a preform to be formed thereon, the apparatus constructed and arranged for securing the preform on the tool forming surface between the first diaphragm and the second diaphragm prior to forming the preform against the tool forming surface when the first diaphragm and second diaphragm are mounted on the apparatus.

2. Apparatus as in claim 1, further comprising a workspace containing the forming tool surface, wherein the first diaphragm and second diaphragm each are inflatable into the workspace.

3. Apparatus as in claim 1, further comprising a workspace containing the forming tool, wherein the first diaphragm and second diaphragm each are inflatable into the workspace.

8. Apparatus as in claim 1, wherein the tool forming surface of the forming tool is nonplanar.

9. Apparatus as in claim 1, wherein the tool forming surface of the forming tool has double curvature.

12. Apparatus as in claim 1 adapted to receive and form a preform having a forming temperature, wherein the first and second diaphragms each have a softening temperature greater than the forming temperature of the preform.

4. Apparatus for forming an article on a surface of a forming tool, comprising:

a first diaphragm mountable on the apparatus and conformable to a preform to be formed;

a second diaphragm mounted on the apparatus and conformable to a portion of the preform simultaneously with the first diaphragm;

a forming tool having a tool forming surface positionable for receiving a preform to be formed thereon between the first diaphragm and the second diaphragm when the first diaphragm and second diaphragm are mounted on the apparatus; and

a lower support for supporting the forming tool and an upper support mounted in opposed relationship with the lower support, the first diaphragm being pneumatically sealable to the upper support and the second diaphragm being pneumatically sealable to the lower support.

39. Apparatus as in claim 4, further comprising a workspace containing the tool forming surface, wherein the first diaphragm and second diaphragm each are inflatable into the workspace 58.

40. Apparatus as in claim 4, wherein the tool forming surface of the forming tool is nonplanar.

41. Apparatus as in claim 4, wherein the tool forming surface of the forming tool has double curvature.

5. Apparatus for forming an article on a surface of a forming tool, comprising:

a first diaphragm mountable on the apparatus and conformable to a preform to be formed;

a second diaphragm mounted on the apparatus and conformable to a portion of the preform simultaneously with the first diaphragm;

a forming tool having a tool forming surface positionable for receiving a preform to be formed thereon between the first diaphragm and the second diaphragm when the first diaphragm and second diaphragm are mounted on the apparatus; and

a support for supporting the forming tool, the second diaphragm being pneumatically sealable to the support and pneumatically sealable to the first diaphragm.

6. Apparatus as in claim 5, wherein the support is a lower support, the apparatus further comprising an upper support mounted in opposed relationship with the lower support.

7. Apparatus for forming an article on a surface of a forming tool, comprising:

a first diaphragm mountable on the apparatus and conformable to a preform to be formed;

a second diaphragm mounted on the apparatus and conformable to a portion of the preform simultaneously with the first diaphragm;

a forming tool having a tool forming surface positionable for receiving a preform to be formed thereon between the first diaphragm and the second diaphragm when the first diaphragm and second diaphragm are mounted on the apparatus,

wherein the first diaphragm includes a first surface that is conformable to a preform and a second surface opposite its first surface that is pneumatically isolable from the tool forming surface, the second diaphragm includes a first surface that is conformable to a preform and a second surface opposite its first surface that is pneumatically isolable from the tool forming surface, and the first surface of the first diaphragm, the first surface of the second diaphragm, and the tool forming surface together define in part a pneumatically isolable cell.

35. Apparatus as in claim 7, further comprising a workspace containing the tool forming surface, wherein the first diaphragm and second diaphragm each are inflatable into the workspace.

36. Apparatus as in claim 7, further comprising a lower support for supporting the forming tool and an upper support mounted in opposed relationship with the lower support, the first diaphragm being pneumatically sealable to the upper support and the second diaphragm being pneumatically sealable to the lower support.

37. Apparatus as in claim 7, wherein the tool forming surface of the forming tool is nonplanar.

38. Apparatus as in claim 7, wherein the tool forming surface of the forming tool has double curvature.

10. Apparatus for forming an article on a surface of a forming tool, comprising:

a first diaphragm mountable on the apparatus and conformable to a preform to be formed, the first diaphragm having a first side for engaging the preform and a second side opposite the first side;

a second diaphragm mounted on the apparatus and conformable to a portion of the preform simultaneously with the first diaphragm;

a forming tool having a tool forming surface positionable for receiving a preform to be formed thereon between the first diaphragm and the second diaphragm when the first diaphragm and second diaphragm are mounted on the apparatus; and

at least one inflatable member inflatable against the second side of the first diaphragm.

11. Apparatus for forming an article on a surface of a forming tool, comprising:

a first diaphragm mountable on the apparatus and conformable to a preform to be formed;

a second diaphragm mounted on the apparatus and conformable to a portion of the preform simultaneously with the first diaphragm, the second diaphragm having a first side for engaging the preform and a second side opposite the first side;

a forming tool having a tool forming surface positionable for receiving a preform to be formed thereon between the first diaphragm and the second diaphragm when the first diaphragm and second diaphragm are mounted on the apparatus; and

at least one inflatable member inflatable against the second side of the second diaphragm.

13. Apparatus for forming an article, comprising:

a forming tool having a tool forming surface for receiving a preform to be formed thereon, the tool forming surface defining in part a first pneumatic cell;

a first diaphragm having a forming surface that is conformable to a preform mounted on the tool forming surface and that defines in part the first pneumatic cell, and a second surface opposite the forming surface that defines in part a second pneumatic cell pneumatically isolable from the first pneumatic cell;

a second diaphragm having a forming surface that is conformable to a preform mounted on the tool forming surface and that, with the tool forming surface and the forming surface of the first diaphragm, defines in part the first pneumatic cell, and a second surface opposite the forming surface that defines in part a third pneumatic cell pneumatically isolable from the first pneumatic cell.

31. Apparatus as in claim 13, further comprising a lower support for supporting the forming tool and an upper support mounted in opposed relationship with the lower support, the first diaphragm being pneumatically sealable to the upper support and the second diaphragm being pneumatically sealable to the lower support.

32. Apparatus as in claim 13, further comprising a workspace containing the forming tool surface, wherein the first diaphragm and second diaphragm each are inflatable into the workspace.

33. Apparatus as in claim 13, wherein the tool forming surface of the forming tool is nonplanar.

34. Apparatus as in claim 13, wherein the tool forming surface of the forming tool has double curvature.

14. Apparatus for forming an article, comprising:

a forming tool having a tool forming surface for receiving a preform to be formed thereon;

a diaphragm having a forming surface that is conformable to a first portion of a preform mounted on the tool forming surface, the diaphragm having a first side for engaging the first portion of the preform and a second side opposite the first side;

at least one inflatable member inflatable against a portion of the second side of the diaphragm that is adjacent the first portion of the preform but that is smaller than the first portion.

15. Apparatus as in claim 14, comprising a plurality of inflatable members inflatable against the second side of the diaphragm.

25. Apparatus as in claim 14, wherein the diaphragm is a first diaphragm, the apparatus further comprising a second diaphragm having a forming surface that is conformable to the preform, the second diaphragm having a first side for engaging the preform and a second side opposite the first side, wherein the first side of the first diaphragm, the first side of the second diaphragm, and the tool forming surface together define in part a pneumatically isolable cell.

26. Apparatus as in claim 25, further comprising a workspace containing the tool forming surface, wherein the first diaphragm and second diaphragm each are inflatable into the workspace.

27. Apparatus as in claim 25, further comprising a workspace containing the forming tool, wherein the first diaphragm and second diaphragm each are inflatable into the workspace.

28. Apparatus as in claim 25, further comprising a support for supporting the forming tool, the second diaphragm being pneumatically sealable to the support and pneumatically sealable to the first diaphragm.

29. Apparatus as in claim 14, wherein the tool forming surface of the forming tool is nonplanar.

30. Apparatus as in claim 14, wherein the tool forming surface of the forming tool has double curvature.

16. Apparatus for forming an article, comprising:

a forming tool having a tool forming surface for receiving a preform to be formed thereon;

a first diaphragm having a forming surface that is conformable to a preform mounted on the tool forming surface, the first diaphragm having a first side for engaging the preform and a second side opposite the first side;

a second diaphragm having a forming surface that is conformable to a preform mounted on the tool forming surface, the second diaphragm having a first side for engaging the preform and a second side opposite the first side; and

at least one inflatable member inflatable against the second side of the second diaphragm.

17. Apparatus as in claim 16, further comprising:

at least one inflatable member inflatable against the second side of the second diaphragm.

18. Apparatus as in claim 17, comprising a plurality of inflatable members inflatable against the second side of the second diaphragm.

19. Apparatus as in claim 16, further comprising a workspace containing the tool forming surface, wherein the first diaphragm and second diaphragm each are inflatable into the workspace.

20. Apparatus as in claim 16, further comprising a lower support for supporting the forming tool and an upper support mounted in opposed relationship with the lower support, the first diaphragm being pneumatically sealable to the upper support and the second diaphragm being pneumatically sealable to the lower support.

21. Apparatus as in claim 16, further comprising a support for supporting the forming tool, the second diaphragm being pneumatically sealable to the support and pneumatically sealable to the first diaphragm.

22. Apparatus as in claim 16, wherein the first diaphragm includes a surface opposite the forming surface of the first diaphragm that is pneumatically isolable from the tool forming surface, the second diaphragm includes a surface opposite the forming surface of the second diaphragm that is pneumatically isolable from the tool forming surface, and the first side of the first diaphragm, the first side of the second diaphragm, and the tool forming surface together define in part a pneumatically isolable cell.

23. Apparatus as in claim 16, wherein the tool forming surface of the forming tool is nonplanar.

24. Apparatus as in claim 16, wherein the tool forming surface of the forming tool has double curvature.