Method and material efficient tooling for continuous compression molding
First Claim
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1. A method of fabricating a thermoplastic laminate part comprising multiple laminate plies using a continuous compression molding line, comprising the steps of;
- placing a lay-up comprising multiple laminate plies in a recess within a tool, the tool comprising a leading end, a central section, and a trailing end, the recess positioned within the central section of the tool; and
,moving the tool through a continuous compression molding line to form the thermoplastic laminate part, the leading end of the tool entering a pulsating drive mechanism before the lay-up enters a pre-forming zone of the continuous compression molding line.
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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.
105 Citations
22 Claims
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1. A method of fabricating a thermoplastic laminate part comprising multiple laminate plies using a continuous compression molding line, comprising the steps of;
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placing a lay-up comprising multiple laminate plies in a recess within a tool, the tool comprising a leading end, a central section, and a trailing end, the recess positioned within the central section of the tool; and
,moving the tool through a continuous compression molding line to form the thermoplastic laminate part, the leading end of the tool entering a pulsating drive mechanism before the lay-up enters a pre-forming zone of the continuous compression molding line. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of fabricating a composite material part comprising multiple laminate plies using a continuous compression molding line, comprising the steps of:
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supporting a lay-up of composite material comprising multiple laminate plies in a recess within a tool, a top of the lay-up within the tool exposed, the top of the lay-up and a length of the recess corresponding respectively to a top and total length of the composite material part, the recess defining a pair of oppositely facing shoulders within a thickness of a central section of the tool; moving the tool through the continuous compression molding line including moving a portion of the tool through the continuous compression molding line and into a pulsating drive mechanism before the lay-up enters the continuous compression molding line; shaping the lay-up into a preformed part as the tool moves through a pre-forming zone of the continuous compression molding line; consolidating the preformed part as the tool moves through a consolidation station of the continuous compression molding line to form the composite material part such that a depth of the recess is substantially equal to a wall thickness of the composite material part; and
,removing the composite material part from the tool. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
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17. A method of fabricating a thermoplastic laminate part comprising multiple laminate plies using a continuous compression molding line, comprising the steps of:
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placing a composite lay-up comprising multiple laminate plies in a recess within a tool; moving the tool through a consolidation station in the continuous compression molding line by pulling a leading end of the tool through the continuous compression molding line; consolidating the composite lay-up into the thermoplastic laminate part at the consolidation station as the tool is pulled through the continuous compression molding line to form the thermoplastic laminate part such that a depth of the recess is substantially equal to a wall thickness of the thermoplastic laminate part; and
,using a trailing end of the tool to maintain an alignment within the consolidation station until the lay-up has been consolidated into the thermoplastic laminate part, a length of the trailing end of the tool being greater than or equal to a length of the consolidation station of the continuous compression molding line. - View Dependent Claims (18, 19, 20, 21, 22)
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Specification