CA2487738A1 - Molding thin wall parts in a closed mold - Google Patents
Molding thin wall parts in a closed mold Download PDFInfo
- Publication number
- CA2487738A1 CA2487738A1 CA 2487738 CA2487738A CA2487738A1 CA 2487738 A1 CA2487738 A1 CA 2487738A1 CA 2487738 CA2487738 CA 2487738 CA 2487738 A CA2487738 A CA 2487738A CA 2487738 A1 CA2487738 A1 CA 2487738A1
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- CA
- Canada
- Prior art keywords
- mold
- mold skin
- skin
- chamber
- mechanical supporting
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
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Classifications
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- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
- B29C33/40—Plastics, e.g. foam or rubber
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- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/30—Mounting, exchanging or centering
- B29C33/308—Adjustable moulds
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- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
- B29C33/565—Consisting of shell-like structures supported by backing material
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- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
-
- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/0011—Moulds or cores; Details thereof or accessories therefor thin-walled moulds
- B29C33/0016—Lost moulds, e.g. staying on the moulded object
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- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
- B29C33/04—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using liquids, gas or steam
-
- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/30—Mounting, exchanging or centering
- B29C33/307—Mould plates mounted on frames; Mounting the mould plates; Frame constructions therefor
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Manufacturing & Machinery (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
MOLDING THIN WALL PARTS IN A CLOSED MOLD
This invention relates to a method of molding thin wall part in a closed mold wherein one or both of the mold parts are formed from a pre-formed flexible mold skin.
BACKGROUND OF THE INVENTION
The present matter relates to the molding of parts which are generally but not necessarily of a composite nature in which a fibre reinforcement layer is infused with a resin to form a relatively thin wall part. In order for the mold elements to be formed cheaply, they are commonly formed as a pre-formed semi-flexible mold skin from a fibre reinforced resin material so that the mold skin has some flexibility.
It is necessary therefore to reinforce the mold skin during the molding process so that it does not flex and thus distort the part.
The resin used is commonly, although not essentially, a thermo setting resin so that it generates heat during the setting or curing process. It is necessary therefore to provide either a lengthy cooling time or to provide techniques for extraction of the heat or "exotherms" from the part as it is setting.
Parts of this nature have conventionally been manufactured in open molding processes in which a resin is applied to a fibrous layer applied onto a mold surface. However this process takes place in the open environment thus releasing potentially toxic materials to the atmosphere. Environmental concerns and regulations have therefore led to the use of techniques which enclose the part from both sides so that the materials emitted are contained in the molding process while the resin is injected or otherwise transferred onto the mold cavity as is well known to one skilled in the art.
In U.S. Patent 6,623,672 (McCollum) issued September 23, 2003 is disclosed a method of molding of the type generally described above in which the position of the flexible mold skin is located by applying behind the mold skin a pressure from a liquid bath. The top and bottom mold skins are similarly supported so that an equal pressure between the top and bottom liquid baths applies a constant pressure throughout the resin within the part which is injected and cured.
The liquid baths can be used to control process temperatures by flowing the liquid through suitable heat exchange systems. The pre-formed semi-flexible mold skins are attached as a closure member on an open face of the liquid bath using peripheral seals.
This arrangement has achieved considerable commercial success and is used to manufacture large numbers of parts such as boat holes.
In U.S. Patent 6,149,844 (Graham) issued November 21, 2000 is disclosed a similar arrangement. This arrangement utilizes a flexible membrane as part of the system. Again the system has the same disadvantage as set forth above.
In PCT published application W02004/054760 (Burgess) published July 1, 2004 is disclosed a method which utilizes a similar pre-formed semi-flexible mold skin in which the mold skin is supported by a series of adjustable pins each having a pivotal head which engages the outside surface of the mold skin.
This invention relates to a method of molding thin wall part in a closed mold wherein one or both of the mold parts are formed from a pre-formed flexible mold skin.
BACKGROUND OF THE INVENTION
The present matter relates to the molding of parts which are generally but not necessarily of a composite nature in which a fibre reinforcement layer is infused with a resin to form a relatively thin wall part. In order for the mold elements to be formed cheaply, they are commonly formed as a pre-formed semi-flexible mold skin from a fibre reinforced resin material so that the mold skin has some flexibility.
It is necessary therefore to reinforce the mold skin during the molding process so that it does not flex and thus distort the part.
The resin used is commonly, although not essentially, a thermo setting resin so that it generates heat during the setting or curing process. It is necessary therefore to provide either a lengthy cooling time or to provide techniques for extraction of the heat or "exotherms" from the part as it is setting.
Parts of this nature have conventionally been manufactured in open molding processes in which a resin is applied to a fibrous layer applied onto a mold surface. However this process takes place in the open environment thus releasing potentially toxic materials to the atmosphere. Environmental concerns and regulations have therefore led to the use of techniques which enclose the part from both sides so that the materials emitted are contained in the molding process while the resin is injected or otherwise transferred onto the mold cavity as is well known to one skilled in the art.
In U.S. Patent 6,623,672 (McCollum) issued September 23, 2003 is disclosed a method of molding of the type generally described above in which the position of the flexible mold skin is located by applying behind the mold skin a pressure from a liquid bath. The top and bottom mold skins are similarly supported so that an equal pressure between the top and bottom liquid baths applies a constant pressure throughout the resin within the part which is injected and cured.
The liquid baths can be used to control process temperatures by flowing the liquid through suitable heat exchange systems. The pre-formed semi-flexible mold skins are attached as a closure member on an open face of the liquid bath using peripheral seals.
This arrangement has achieved considerable commercial success and is used to manufacture large numbers of parts such as boat holes.
In U.S. Patent 6,149,844 (Graham) issued November 21, 2000 is disclosed a similar arrangement. This arrangement utilizes a flexible membrane as part of the system. Again the system has the same disadvantage as set forth above.
In PCT published application W02004/054760 (Burgess) published July 1, 2004 is disclosed a method which utilizes a similar pre-formed semi-flexible mold skin in which the mold skin is supported by a series of adjustable pins each having a pivotal head which engages the outside surface of the mold skin.
The disclosures of the above three documents are incorporated herein by reference or should be referred to for further information concerning the structures and processes relevant to this invention.
SUMMARY OF THE INVENTION
It is one object of the invention to provide an improved method for molding parts in which the pre-formed semi-flexible mold skin is accurately and effectively constrained.
According to one aspect of the invention there is provided a method of molding parts from a settable resin material comprising:
providing a first mold part and a second mold part which are arranged when brought together to define a cavity therebetween within which the resin can be injected at molding pressures and caused to set for forming the part in a molding process;
at least one of the mold parts comprising a pre-formed mold skin formed from a material which is flexible under the molding pressures;
providing a liquid in a chamber arranged to provide thermal contact with the mold skin for changing the temperature thereof during the molding process;
and providing a plurality of mechanical supporting elements for providing a supporting engagement with the mold skin at a plurality of spaced positions across the mold skin to prevent distortion of the mold skin during the molding, each mechanical supporting element including an engagement head portion and an adjustable portion such that actuation of the adjustment portions causes movement of the head portion relative to the mold skin to accommodate different mold skins.
The parts to be molded are commonly composite parts which include fiber reinforcement laid in the cavity but this is not essential to the invention.
Commonly the mold skin is pre-formed from fiber reinforced plastics of a relatively thin wall so as to be light weight and inexpensive to manufacture, but such mold skins are flexible under pressure so that they will distort if not properly supported. However other manufacturing materials and structures can be used for the mold skin.
The thickness of the mold skin may be constant over the whole area of the mold but also it may vary by additional material, such as fiber reinforcement, being applied at certain areas. The head portions are thus brought up to the exterior of the mold skin at whatever position it is located relative to the inner surface for accurate support and location of the mold skin.
The mold skin may be formed on its exterior surface with specific engagement points or pads defined on the mold skin for engaging specific head points for accuracy. Thus for high accuracy, the mold skin may include a specific shape and defined points which match a computer controlled head and support array. In this way the mold skin can be quickly and accurately located by computer control of the head location.
In less accurate systems required for cheaper parts where tolerances can be higher, the adjustment of the heads on the adjustable supports can be carried out manually up to the exterior of the mold skin wherever that may be depending on the thickness of the mold skin.
While the definitions and specific examples referred to herein mention first and second mold elements it will be appreciated that more than two can be used 5 in many examples depending on the shape and complexity of the mold.
The adjustment portions can have both fine and course movements so that adjustment over several inches can be effected quickly by a first adjustment action followed by fine adjustment over small distances of the order of 0.0005 inch for high accuracy parts and of the order of 0.005 inch for parts of less required accuracy.
The mold elements may also include not only reinforcing fibers but also other elements of the part such as gel coats, fasteners, inserts all well known to one skilled in the art.
While the description herein refers to manufacture of a part, it will of course be appreciated that more than one part can be formed on the same mold element by arranging mold skins side by side for simultaneous side by side manufacture.
The methods disclosed herein allow significant protection of the environment by reducing emissions of potentially damaging materials formed in the molding process while allowing a system to be manufactures which is potentially of low cost for the low cost or smaller manufacturer. Alternatively the same concepts can be used for high accuracy high complexity machines using expensive computer control.
SUMMARY OF THE INVENTION
It is one object of the invention to provide an improved method for molding parts in which the pre-formed semi-flexible mold skin is accurately and effectively constrained.
According to one aspect of the invention there is provided a method of molding parts from a settable resin material comprising:
providing a first mold part and a second mold part which are arranged when brought together to define a cavity therebetween within which the resin can be injected at molding pressures and caused to set for forming the part in a molding process;
at least one of the mold parts comprising a pre-formed mold skin formed from a material which is flexible under the molding pressures;
providing a liquid in a chamber arranged to provide thermal contact with the mold skin for changing the temperature thereof during the molding process;
and providing a plurality of mechanical supporting elements for providing a supporting engagement with the mold skin at a plurality of spaced positions across the mold skin to prevent distortion of the mold skin during the molding, each mechanical supporting element including an engagement head portion and an adjustable portion such that actuation of the adjustment portions causes movement of the head portion relative to the mold skin to accommodate different mold skins.
The parts to be molded are commonly composite parts which include fiber reinforcement laid in the cavity but this is not essential to the invention.
Commonly the mold skin is pre-formed from fiber reinforced plastics of a relatively thin wall so as to be light weight and inexpensive to manufacture, but such mold skins are flexible under pressure so that they will distort if not properly supported. However other manufacturing materials and structures can be used for the mold skin.
The thickness of the mold skin may be constant over the whole area of the mold but also it may vary by additional material, such as fiber reinforcement, being applied at certain areas. The head portions are thus brought up to the exterior of the mold skin at whatever position it is located relative to the inner surface for accurate support and location of the mold skin.
The mold skin may be formed on its exterior surface with specific engagement points or pads defined on the mold skin for engaging specific head points for accuracy. Thus for high accuracy, the mold skin may include a specific shape and defined points which match a computer controlled head and support array. In this way the mold skin can be quickly and accurately located by computer control of the head location.
In less accurate systems required for cheaper parts where tolerances can be higher, the adjustment of the heads on the adjustable supports can be carried out manually up to the exterior of the mold skin wherever that may be depending on the thickness of the mold skin.
While the definitions and specific examples referred to herein mention first and second mold elements it will be appreciated that more than two can be used 5 in many examples depending on the shape and complexity of the mold.
The adjustment portions can have both fine and course movements so that adjustment over several inches can be effected quickly by a first adjustment action followed by fine adjustment over small distances of the order of 0.0005 inch for high accuracy parts and of the order of 0.005 inch for parts of less required accuracy.
The mold elements may also include not only reinforcing fibers but also other elements of the part such as gel coats, fasteners, inserts all well known to one skilled in the art.
While the description herein refers to manufacture of a part, it will of course be appreciated that more than one part can be formed on the same mold element by arranging mold skins side by side for simultaneous side by side manufacture.
The methods disclosed herein allow significant protection of the environment by reducing emissions of potentially damaging materials formed in the molding process while allowing a system to be manufactures which is potentially of low cost for the low cost or smaller manufacturer. Alternatively the same concepts can be used for high accuracy high complexity machines using expensive computer control.
The liquid which is contained in the chamber is generally water but others can be used.
The liquid which is contained in the chamber can be maintained stationary in the chamber or can be caused to flow through the chamber to carry heat to or from the part as required.
In one preferred arrangement, the liquid is arranged in the chamber so as to be in directly contact with an outside surface of the mold skin.
In another preferred arrangement, there is provided a flexible membrane between the liquid and an outside surface of the mold skin.
In one preferred arrangement, the mechanical supporting elements each include at least a part extending through the chamber.
Alternatively the adjustment portion of the mechanical supporting elements is mounted in the chamber.
Preferably the adjustment portion of the mechanical supporting elements is mounted outside the chamber and each mechanical supporting element has a portion extending into the chamber. Thus there may be provided a seal on the portion at the location where it enters the chamber or there is provided a jacket on the part of the mechanical supporting elements within the chamber.
In one optional arrangement, the head portion comprises a separate element or plate or bar which is supported by two or more adjustment portions.
However the head may be defined simply by the end of the adjustment portion in the form of a pin of shaft. Alternatively each pin or shaft may have its own head mounted thereon as a pivotal member with a pad or surface in contact with the exterior of the mold skin. Alternatively a combination of plates and bars and heads may be used designed to support different parts and shapes and angles of the mold skin and these elements may be supported by one or more pins as required depending on their shape and the forces involved.
In one preferred arrangement, the chamber is closed and is defined by a plurality of fixed walls leaving one side open and wherein the mold skin is located at the open side.
In another preferred arrangement, the mold skin sits on a flexible membrane covering the liquid in the chamber such that the mold skin is removed from the membrane leaving the membrane covering the chamber.
In one preferred arrangement, the mold skin is removed with the part and thus is freely rested or placed on its support. This allows the part and the mold skin to be removed prior to the complete curing of the material and to remain supported while the curing is completed. In this way the main part of the molding system can be used to mold another part with another mold skin while the first is curing to speed up processing and increase rate of manufacture.
In another preferred arrangement, there is provided a backing wall generally following the shape of the mold skin and wherein the liquid is contained between the mold skin and the backing wall.
In this arrangement, the liquid can be contained in a flexible bag or mattress which lies underneath or behind the mold skin. The bag is preferably shaped to form a container for a constant thickness layer of the liquid in the form of a mattress. The bag is preferably self-contained so as to be portable. The bag is preferably closed so that it can be pressurized by the liquid to provide an approximately constant pressure over its surface contacting the mold skin. The bag may have one or more outlets and inlets for passage of the temperature controlling fluid therethrough.
In this arrangement, the backing wall can be flexible and the mechanical supporting elements are arranged to engage the backing wall so as to transfer forces to the mold skin through the liquid, which is preferably contained in the bag so that it can be pressurized, contained, manageable and portable. The backing wall preferably approximately follows the shape of the outside surface of the mold skin so that the liquid layer is of constant thickness. However this may be approximate thus allowing the support to be manufactured cheaply. Also the support may be deliberately shaped to depart from the shape of the outside surface of the mold skin so as to apply deliberately increased pressure on the bag and the liquid at hard to contact places on the mold skin to better maintain contact by the bag on the mold skin over its full extent.
The backing support may be the same size and overall shape as the mold skin but may also be formed in separate parts where desirable for easier manipulation. This also can be formed into a modular system in which additional supports and bags are used side by side to support a larger mold skin.
r In this arrangement, the backing wall may have holes therein through which the mechanical supporting elements extend for applying forces to the mold skin.
In this arrangement, the mechanical supporting elements may directly engage the outside surface of the mold skin through holes in the flexible bag.
In this arrangement, the flexible bag may have inner and outer walls which have parts which are touched together at the mechanical supporting elements so that the mechanical supporting elements apply force directly to the outer surface of the mold skin, where the inner and outer walls are connected by bonding heat sealing at the touching parts.
The mold skin may be removed from the flexible bag with the part in some cases. Thus the mold skin simply rests on the bag and can be lifted away from the bag to support the part during cooling. Yet further the mold skin may remain in place for the molding of the next part.
Alternatively in some cases where the heat transfer effect of the liquid is required the mold skin and the flexible bag and the backing wall are all removed with the part.
In this arrangement, the backing wall may be formed from the same material as the mold skin and is matched in shape to the mold skin.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
Figure 1 is a cross sectional view showing a first embodiment of molding system and method according to the present invention.
Figure 2 is a cross sectional view showing a second embodiment of molding system and method according to the present invention.
5 Figure 3 is a cross sectional view showing a third embodiment of molding system and method according to the present invention.
Figure 4 is a cross sectional view showing a fourth embodiment of molding system and method according to the present invention.
In the drawings like characters of reference indicate corresponding 10 parts in the different figures.
DETAILED DESCRIPTION
In Figure 1 is shown a first embodiment of a molding system and method according to the present invention. The system includes an upper mold element 10 and a lower mold element 11 which can be moved to provide a cavity therebetween into which resin is injected by a resin injection system 13 to form the part shaped and arranged in accordance with the shape of the mold elements.
The resin injection system 13 is well known to one skilled in the art so that detailed description thereof is not necessary herein. Many examples of prior arrangements of this type are available in the prior art.
The part formed is generally a composite part including fibre layer reinforcement and the fibre layers may be loaded onto the lower mold element prior to closing of the mold. Again the techniques for applying the fibre layers are well known to one skilled in the art.
The upper mold element 10 is movable on a lift system 14 which allows it to be removed from the lower mold element to access the cavity 12 and to access the finished part. Again the lift mechanism is available to one skilled in the art.
The lower mold element 11 is shown in detail herein and will be described hereinafter. The upper mold element 10 is shown only schematically and this may be simply a fixed element with a bottom surface shaped to the required shape or it may more preferably be a symmetrical arrangement substantially identical to the construction described in respect of element 11.
Suitable sealing arrangements are provided around the outside edges between the mold elements so that the injection of the resin 13 allows the resin to fill the cavity 12, to expel any air or air bubbles and to compress the resin within the fibrous layers applied within the cavity 12.
The mold element 11 comprises a bath 15 formed from a base wall 16 and upstanding side walls 17 leaving an open upper mouth of the bath defined by peripheral edges 18 of the side walls 17. The baths can be filled with a liquid 19 which is generally water and the water can be supplied into and out of the bath through conduits 20 and 21 to a heat exchange system for example of the type disclosed in the above US patents. This allows the bath to be maintained at a required temperature during the molding process which can be varied by changing the temperature of the incoming flowing liquid from the heat exchange system.
The open mouth of the bath is closed by a flexible membrane 21 which is attached to the peripheral edge 18. The membrane 21 can flex to the required position as required to accommodate the exterior shape of the mold skin which is the same as or approximates to the shape of the article to beg molded.
On the membrane 21 is supported a bottorn mold skin 22 which is pre-formed and semi-flexible for example formed from fibreglass so as to define an upper surface which provides the shaping of the part to be molded within the cavity 12.
In the embodiment shown the mold skin is a simple generally channel shaped element for example for forming the hull of a~ boat. However it will be appreciated that other shapes which are more complex can be provided. The shapes may also have a deeper recess at the center than the generally simple channel shape as shown but of course this may require different shape and arrangement of the bath and may require different shape and arrangement of the membrane.
The mold skin being semi-flexible is therefore of a nature which will flex under the pressures involved in the injection of the resin into the cavity 12.
The mold skin is therefore supported by a plurality of mechanical supporting elements each indicated at 23. In the embodiment shown the mechanical support elements 23 include a head 24 and an adjustable portion 25 which can move the head towards and away from the mold skin 22 by a linear actuator 26. This can include course and fine movements and the fine movements can be provided by rotation of a screw either by rotating the pin or a nut carried on the pin.
In the embodiment shown the adjustable portion is in the form of a shaft extending at right angles to the base 15. The shaft passes through a seal 27 in the base 15 so that a portion of the shaft is exterior of the base 15 and a portion is located within the liquid 19. The seal 27 prevents the escape of a liquid while the shaft can be moved upwardly and downwardly by the linear actuator 26. The movement of the shaft can be effected by any suitable mechanism well known to one skilled in the art for moving such a shaft along its axis, This can be provided simply by manual movement of the shaft and locking of the shaft via a sleeve and screw. More complex arrangements can be provided using linear actuator motors where the motor is accurately driven by a numerically controlled machine so that the accurate location of the shaft can be determined. The head 24 is in the form of a plate having an upper surface 30 arranged to engage on a flat portion of the outside surface of the mold skin. The plate 30 is pivotal relative to the end of the shaft on a suitable pivot mounting 31 which is preferably universal in pivotal action so that the face of the head can be adjusted to the required orientation to engage the outside surface regardless of the angle of the outside surface.
On the left hand side of the figure is shown three such mechanical supporting elements each of which comprises an individual head supported on an individual shaft.
On the right hand side there are shown alternative arrangements wherein a first mechanical supporting element generally indicated at 32 includes a head 33 which is supported by two or more shafts 34 and 35. The head 33 thus bridges the shafts 34 and 35 and is pivotally connected to each at a respective pivot mounting 36. This allows the angle of the head 39 to be adjusted relative to the horizontal so as to accommodate differences of angle of the surface of the mold skin which is engaged by the head 33.
At mechanical support element 38 there is provided a further arrangement in which a head 39 is carried on one or more shafts 40. The head in this arrangement is more complex in that it is shaped to accommodate different shapes of the outside surface of the mold skin other than simply flat planar portions.
In the embodiment shown the shape is defined by an apex between two surfaces.
However other arrangements can be supported using a shaped head of this type including recessed portions, channels, ribs and the like.
In one mode of operation of the arrangement shown in Figure 1, after injection of the resin 13 into the fibrous layer, the components are left in position during the curing action of a resin utilizing the bath liquid 19 for controlling the temperature and the exotherms from the curing process.
In an alternative arrangement, after the resin has been injected and an initial curing action has occurred, the top mold 10 can be lifted away exposing the part sitting on the semi-flexible mold skin 22. The mold skin and the part can then be lifted from the membrane since the mold skin may simply sit loosely on the membrane and is free to be removed therefrom allowing the part and the mold skin to be lifted away to a support cradle where the mold skin is supported for completing r the curing action till the part can be removed from the mold skin. In this mode of operation, a further mold skin identical to the first can be inserted onto the support elements and the membrane so that further molding can occur while the first part is completing its curing action. In this way the rate of molding can be significantly 5 increased by having a series of partly cured parts in stations around the single molding system with each mold skin being returned to the molding system when its part is fully cured.
In some cases the mold skin is fastened to the frame and thus remains attached thereto until changed for a new part.
10 It will be appreciated that when a new part is to be molded, new mold skins can be supplied and inserted one at a time onto the flexible membrane with the support elements being adjusted to the required position to report that particular mold skin. This can be carried out manually or can be carried out utilizing a numerical (PLC) controlled machine to actuate the movement of the adjustment 15 portions so that the heads are moved to the required locations. In certain circumstances different head scan be selected.
Thus the shape of the semi-flexible mold skin is maintained accurately by the support thereof by the heads of the mechanical supporting elements. The number and arrangement of the heads is selected in dependence upon the shape and design of the mold skin to ensure accurate support of the mold skin. It will be appreciated that different shapes of mold skin will have different forces in different directions and thus will require different positioning of the supports. In practice, r therefore, an array of such supporting elements can be provided and can be selected with different heads to provide different supporting effects as required.
Thus the pivot mounting 31 of each head can allow the head to be removed and replaced. Turning now to Figure 2 there is shown an arrangement similar to that of Figure 1 in that it includes the bath 15A supporting a semi-flexible pre-formed mold skin 22A. In this arrangement there is no flexible membrane and the mold skin is itself attached to the upper periphery 18.
A further modification shown in Figure 2 utilizes a frame arrangement 50 which supports the actuators 26A for the adjustable portions 25A carrying the heads 24A. The frame 50 is mounted within the bath and is enclosed within an enclosure 51 so that the actuators 26A are protected from the water 19A. In this arrangement the adjustment portion 25A or the shafts are contained within flexible sleeves 53 which exclude the water 19A from contacting the shaft 25A.
It will be appreciated that the arrangement utilizing the mold skin directly on the surface of the bath can be used with the support arrangement for the actuators where they are exterior as shown in Figure 1.
Turning now to Figure 3 there is shown a further alternative arrangement in which the mold skin 22B is supported on a flexible bag or bladder 60 having an upper sheet 61 sealed around its edges to a lower sheet 62 and forming therebetween a cavity 63 for receiving the liquid 19B. The bladder or bag 60 is supported on a second mold skin 64 which is shaped identically to the mold skin 22B
and formed from similar material so that it is another one of the mold skins of the array of mold skins which can be used in the molding process. The mechanical supports 23B are substantially the same as previously described and support the second mold skin 64. In this way the bladder 60 is contained within the two mold skins and acts to support accurately the mold skin 22B at its required position since there is a constant pressure through the bladder and the liquid 19B therein and since the outer mold skin exactly matches the shape of the mold skin 22B which acts to form the part.
The liquid 19B can be stationary or can be circulated as previously described to control temperature at the molding process. The mold skin 22B can remain in place during the complete molding process or can be removed partway through the curing for separate support and completion of the curing action so that the system can be used for further molding action as previously described.
The embodiment shown in Figure 4 is similar to that of Figure 3 in that it includes the mold skin 22C supported on a second outer mold skin 64C. The system is again supported by the mechanical support elements 23C as previously described. However in this arrangement the actuators 23C project through holes in the lower mold skin 64C. In addition the bladder 60C is formed with points 71 in which the bottom layer 62C is touched to the top layer 61 C. At these points it can be heat sealed or otherwise connected so that the bladder has dimples or quilt points across its area both in transverse or longitudinally spaced array. Thus the pins or support elements 23C, also arranged in an array longitudinally and transversely spaced project through the holes 70 and engage against the points 71 so that the head of the pin provides a force pressing directly against the inner mold skin through the thicknesses of the top and bottom layer of the bladder which are in contact. The durometer of the bladder can be selected to allow compression of the bag material to an amount to control the compression of the resin in the cavity for control of the thickness and thus resin content of the final part. The outer mold skin 64C can be supported by additional pins (not shown) or by suitable shaped support plates or other suitable supports which hold it in place accurately spaced form the main mold skin.
As the point 71 are spaced in an array, the liquid 19C covers the majority of the area within the bladder and can either remain stationary and can flow as previously described. The support elements 23C can be provided with heads as previously described and can form nearly the upper end of a shaft or pin.
The arrangement disclosed in Figures 3 and 4 thus provides a three layer sandwich of:
1 ) Mold skin 2) Water bed (for self contained exotherm management).
3) Shaped support of water bed by separate mold skin.
In a first method of operation, the mold skin is directly moved by set of PLC structural pins. Then waterbed and waterbed support mold skin are moved by a separate set of pins until they contact the mold skin. Pins slide through holes in the water bed layer (made in a regular grid layout so the pattern fits all molds). The water is temperature and flow controlled within the water bed layer.
In a second method which is basically the same as but there are no holes in water bed layer. Instead only the support skin layer is moved by actuators and the first set of pins is eliminated. The bridged pins may be best for this.
The pins can be as noted above can move through holes in the support skin but not through the water bed. Instead the pins flexibly push the sides of the water bed against the mold skin.
The following options can be included:
The pins can be single or bridged and can be in any number as required.
Optional walls can be added to support skin to assist in containment of water bag.
The water bag can be pressurized to assist in molding quality.
The water bag can be attached or detached from either or both mold skins to assist in molding logistics.
The water can circulate in the water bed and can be hot or cold.
Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departure from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
The liquid which is contained in the chamber can be maintained stationary in the chamber or can be caused to flow through the chamber to carry heat to or from the part as required.
In one preferred arrangement, the liquid is arranged in the chamber so as to be in directly contact with an outside surface of the mold skin.
In another preferred arrangement, there is provided a flexible membrane between the liquid and an outside surface of the mold skin.
In one preferred arrangement, the mechanical supporting elements each include at least a part extending through the chamber.
Alternatively the adjustment portion of the mechanical supporting elements is mounted in the chamber.
Preferably the adjustment portion of the mechanical supporting elements is mounted outside the chamber and each mechanical supporting element has a portion extending into the chamber. Thus there may be provided a seal on the portion at the location where it enters the chamber or there is provided a jacket on the part of the mechanical supporting elements within the chamber.
In one optional arrangement, the head portion comprises a separate element or plate or bar which is supported by two or more adjustment portions.
However the head may be defined simply by the end of the adjustment portion in the form of a pin of shaft. Alternatively each pin or shaft may have its own head mounted thereon as a pivotal member with a pad or surface in contact with the exterior of the mold skin. Alternatively a combination of plates and bars and heads may be used designed to support different parts and shapes and angles of the mold skin and these elements may be supported by one or more pins as required depending on their shape and the forces involved.
In one preferred arrangement, the chamber is closed and is defined by a plurality of fixed walls leaving one side open and wherein the mold skin is located at the open side.
In another preferred arrangement, the mold skin sits on a flexible membrane covering the liquid in the chamber such that the mold skin is removed from the membrane leaving the membrane covering the chamber.
In one preferred arrangement, the mold skin is removed with the part and thus is freely rested or placed on its support. This allows the part and the mold skin to be removed prior to the complete curing of the material and to remain supported while the curing is completed. In this way the main part of the molding system can be used to mold another part with another mold skin while the first is curing to speed up processing and increase rate of manufacture.
In another preferred arrangement, there is provided a backing wall generally following the shape of the mold skin and wherein the liquid is contained between the mold skin and the backing wall.
In this arrangement, the liquid can be contained in a flexible bag or mattress which lies underneath or behind the mold skin. The bag is preferably shaped to form a container for a constant thickness layer of the liquid in the form of a mattress. The bag is preferably self-contained so as to be portable. The bag is preferably closed so that it can be pressurized by the liquid to provide an approximately constant pressure over its surface contacting the mold skin. The bag may have one or more outlets and inlets for passage of the temperature controlling fluid therethrough.
In this arrangement, the backing wall can be flexible and the mechanical supporting elements are arranged to engage the backing wall so as to transfer forces to the mold skin through the liquid, which is preferably contained in the bag so that it can be pressurized, contained, manageable and portable. The backing wall preferably approximately follows the shape of the outside surface of the mold skin so that the liquid layer is of constant thickness. However this may be approximate thus allowing the support to be manufactured cheaply. Also the support may be deliberately shaped to depart from the shape of the outside surface of the mold skin so as to apply deliberately increased pressure on the bag and the liquid at hard to contact places on the mold skin to better maintain contact by the bag on the mold skin over its full extent.
The backing support may be the same size and overall shape as the mold skin but may also be formed in separate parts where desirable for easier manipulation. This also can be formed into a modular system in which additional supports and bags are used side by side to support a larger mold skin.
r In this arrangement, the backing wall may have holes therein through which the mechanical supporting elements extend for applying forces to the mold skin.
In this arrangement, the mechanical supporting elements may directly engage the outside surface of the mold skin through holes in the flexible bag.
In this arrangement, the flexible bag may have inner and outer walls which have parts which are touched together at the mechanical supporting elements so that the mechanical supporting elements apply force directly to the outer surface of the mold skin, where the inner and outer walls are connected by bonding heat sealing at the touching parts.
The mold skin may be removed from the flexible bag with the part in some cases. Thus the mold skin simply rests on the bag and can be lifted away from the bag to support the part during cooling. Yet further the mold skin may remain in place for the molding of the next part.
Alternatively in some cases where the heat transfer effect of the liquid is required the mold skin and the flexible bag and the backing wall are all removed with the part.
In this arrangement, the backing wall may be formed from the same material as the mold skin and is matched in shape to the mold skin.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
Figure 1 is a cross sectional view showing a first embodiment of molding system and method according to the present invention.
Figure 2 is a cross sectional view showing a second embodiment of molding system and method according to the present invention.
5 Figure 3 is a cross sectional view showing a third embodiment of molding system and method according to the present invention.
Figure 4 is a cross sectional view showing a fourth embodiment of molding system and method according to the present invention.
In the drawings like characters of reference indicate corresponding 10 parts in the different figures.
DETAILED DESCRIPTION
In Figure 1 is shown a first embodiment of a molding system and method according to the present invention. The system includes an upper mold element 10 and a lower mold element 11 which can be moved to provide a cavity therebetween into which resin is injected by a resin injection system 13 to form the part shaped and arranged in accordance with the shape of the mold elements.
The resin injection system 13 is well known to one skilled in the art so that detailed description thereof is not necessary herein. Many examples of prior arrangements of this type are available in the prior art.
The part formed is generally a composite part including fibre layer reinforcement and the fibre layers may be loaded onto the lower mold element prior to closing of the mold. Again the techniques for applying the fibre layers are well known to one skilled in the art.
The upper mold element 10 is movable on a lift system 14 which allows it to be removed from the lower mold element to access the cavity 12 and to access the finished part. Again the lift mechanism is available to one skilled in the art.
The lower mold element 11 is shown in detail herein and will be described hereinafter. The upper mold element 10 is shown only schematically and this may be simply a fixed element with a bottom surface shaped to the required shape or it may more preferably be a symmetrical arrangement substantially identical to the construction described in respect of element 11.
Suitable sealing arrangements are provided around the outside edges between the mold elements so that the injection of the resin 13 allows the resin to fill the cavity 12, to expel any air or air bubbles and to compress the resin within the fibrous layers applied within the cavity 12.
The mold element 11 comprises a bath 15 formed from a base wall 16 and upstanding side walls 17 leaving an open upper mouth of the bath defined by peripheral edges 18 of the side walls 17. The baths can be filled with a liquid 19 which is generally water and the water can be supplied into and out of the bath through conduits 20 and 21 to a heat exchange system for example of the type disclosed in the above US patents. This allows the bath to be maintained at a required temperature during the molding process which can be varied by changing the temperature of the incoming flowing liquid from the heat exchange system.
The open mouth of the bath is closed by a flexible membrane 21 which is attached to the peripheral edge 18. The membrane 21 can flex to the required position as required to accommodate the exterior shape of the mold skin which is the same as or approximates to the shape of the article to beg molded.
On the membrane 21 is supported a bottorn mold skin 22 which is pre-formed and semi-flexible for example formed from fibreglass so as to define an upper surface which provides the shaping of the part to be molded within the cavity 12.
In the embodiment shown the mold skin is a simple generally channel shaped element for example for forming the hull of a~ boat. However it will be appreciated that other shapes which are more complex can be provided. The shapes may also have a deeper recess at the center than the generally simple channel shape as shown but of course this may require different shape and arrangement of the bath and may require different shape and arrangement of the membrane.
The mold skin being semi-flexible is therefore of a nature which will flex under the pressures involved in the injection of the resin into the cavity 12.
The mold skin is therefore supported by a plurality of mechanical supporting elements each indicated at 23. In the embodiment shown the mechanical support elements 23 include a head 24 and an adjustable portion 25 which can move the head towards and away from the mold skin 22 by a linear actuator 26. This can include course and fine movements and the fine movements can be provided by rotation of a screw either by rotating the pin or a nut carried on the pin.
In the embodiment shown the adjustable portion is in the form of a shaft extending at right angles to the base 15. The shaft passes through a seal 27 in the base 15 so that a portion of the shaft is exterior of the base 15 and a portion is located within the liquid 19. The seal 27 prevents the escape of a liquid while the shaft can be moved upwardly and downwardly by the linear actuator 26. The movement of the shaft can be effected by any suitable mechanism well known to one skilled in the art for moving such a shaft along its axis, This can be provided simply by manual movement of the shaft and locking of the shaft via a sleeve and screw. More complex arrangements can be provided using linear actuator motors where the motor is accurately driven by a numerically controlled machine so that the accurate location of the shaft can be determined. The head 24 is in the form of a plate having an upper surface 30 arranged to engage on a flat portion of the outside surface of the mold skin. The plate 30 is pivotal relative to the end of the shaft on a suitable pivot mounting 31 which is preferably universal in pivotal action so that the face of the head can be adjusted to the required orientation to engage the outside surface regardless of the angle of the outside surface.
On the left hand side of the figure is shown three such mechanical supporting elements each of which comprises an individual head supported on an individual shaft.
On the right hand side there are shown alternative arrangements wherein a first mechanical supporting element generally indicated at 32 includes a head 33 which is supported by two or more shafts 34 and 35. The head 33 thus bridges the shafts 34 and 35 and is pivotally connected to each at a respective pivot mounting 36. This allows the angle of the head 39 to be adjusted relative to the horizontal so as to accommodate differences of angle of the surface of the mold skin which is engaged by the head 33.
At mechanical support element 38 there is provided a further arrangement in which a head 39 is carried on one or more shafts 40. The head in this arrangement is more complex in that it is shaped to accommodate different shapes of the outside surface of the mold skin other than simply flat planar portions.
In the embodiment shown the shape is defined by an apex between two surfaces.
However other arrangements can be supported using a shaped head of this type including recessed portions, channels, ribs and the like.
In one mode of operation of the arrangement shown in Figure 1, after injection of the resin 13 into the fibrous layer, the components are left in position during the curing action of a resin utilizing the bath liquid 19 for controlling the temperature and the exotherms from the curing process.
In an alternative arrangement, after the resin has been injected and an initial curing action has occurred, the top mold 10 can be lifted away exposing the part sitting on the semi-flexible mold skin 22. The mold skin and the part can then be lifted from the membrane since the mold skin may simply sit loosely on the membrane and is free to be removed therefrom allowing the part and the mold skin to be lifted away to a support cradle where the mold skin is supported for completing r the curing action till the part can be removed from the mold skin. In this mode of operation, a further mold skin identical to the first can be inserted onto the support elements and the membrane so that further molding can occur while the first part is completing its curing action. In this way the rate of molding can be significantly 5 increased by having a series of partly cured parts in stations around the single molding system with each mold skin being returned to the molding system when its part is fully cured.
In some cases the mold skin is fastened to the frame and thus remains attached thereto until changed for a new part.
10 It will be appreciated that when a new part is to be molded, new mold skins can be supplied and inserted one at a time onto the flexible membrane with the support elements being adjusted to the required position to report that particular mold skin. This can be carried out manually or can be carried out utilizing a numerical (PLC) controlled machine to actuate the movement of the adjustment 15 portions so that the heads are moved to the required locations. In certain circumstances different head scan be selected.
Thus the shape of the semi-flexible mold skin is maintained accurately by the support thereof by the heads of the mechanical supporting elements. The number and arrangement of the heads is selected in dependence upon the shape and design of the mold skin to ensure accurate support of the mold skin. It will be appreciated that different shapes of mold skin will have different forces in different directions and thus will require different positioning of the supports. In practice, r therefore, an array of such supporting elements can be provided and can be selected with different heads to provide different supporting effects as required.
Thus the pivot mounting 31 of each head can allow the head to be removed and replaced. Turning now to Figure 2 there is shown an arrangement similar to that of Figure 1 in that it includes the bath 15A supporting a semi-flexible pre-formed mold skin 22A. In this arrangement there is no flexible membrane and the mold skin is itself attached to the upper periphery 18.
A further modification shown in Figure 2 utilizes a frame arrangement 50 which supports the actuators 26A for the adjustable portions 25A carrying the heads 24A. The frame 50 is mounted within the bath and is enclosed within an enclosure 51 so that the actuators 26A are protected from the water 19A. In this arrangement the adjustment portion 25A or the shafts are contained within flexible sleeves 53 which exclude the water 19A from contacting the shaft 25A.
It will be appreciated that the arrangement utilizing the mold skin directly on the surface of the bath can be used with the support arrangement for the actuators where they are exterior as shown in Figure 1.
Turning now to Figure 3 there is shown a further alternative arrangement in which the mold skin 22B is supported on a flexible bag or bladder 60 having an upper sheet 61 sealed around its edges to a lower sheet 62 and forming therebetween a cavity 63 for receiving the liquid 19B. The bladder or bag 60 is supported on a second mold skin 64 which is shaped identically to the mold skin 22B
and formed from similar material so that it is another one of the mold skins of the array of mold skins which can be used in the molding process. The mechanical supports 23B are substantially the same as previously described and support the second mold skin 64. In this way the bladder 60 is contained within the two mold skins and acts to support accurately the mold skin 22B at its required position since there is a constant pressure through the bladder and the liquid 19B therein and since the outer mold skin exactly matches the shape of the mold skin 22B which acts to form the part.
The liquid 19B can be stationary or can be circulated as previously described to control temperature at the molding process. The mold skin 22B can remain in place during the complete molding process or can be removed partway through the curing for separate support and completion of the curing action so that the system can be used for further molding action as previously described.
The embodiment shown in Figure 4 is similar to that of Figure 3 in that it includes the mold skin 22C supported on a second outer mold skin 64C. The system is again supported by the mechanical support elements 23C as previously described. However in this arrangement the actuators 23C project through holes in the lower mold skin 64C. In addition the bladder 60C is formed with points 71 in which the bottom layer 62C is touched to the top layer 61 C. At these points it can be heat sealed or otherwise connected so that the bladder has dimples or quilt points across its area both in transverse or longitudinally spaced array. Thus the pins or support elements 23C, also arranged in an array longitudinally and transversely spaced project through the holes 70 and engage against the points 71 so that the head of the pin provides a force pressing directly against the inner mold skin through the thicknesses of the top and bottom layer of the bladder which are in contact. The durometer of the bladder can be selected to allow compression of the bag material to an amount to control the compression of the resin in the cavity for control of the thickness and thus resin content of the final part. The outer mold skin 64C can be supported by additional pins (not shown) or by suitable shaped support plates or other suitable supports which hold it in place accurately spaced form the main mold skin.
As the point 71 are spaced in an array, the liquid 19C covers the majority of the area within the bladder and can either remain stationary and can flow as previously described. The support elements 23C can be provided with heads as previously described and can form nearly the upper end of a shaft or pin.
The arrangement disclosed in Figures 3 and 4 thus provides a three layer sandwich of:
1 ) Mold skin 2) Water bed (for self contained exotherm management).
3) Shaped support of water bed by separate mold skin.
In a first method of operation, the mold skin is directly moved by set of PLC structural pins. Then waterbed and waterbed support mold skin are moved by a separate set of pins until they contact the mold skin. Pins slide through holes in the water bed layer (made in a regular grid layout so the pattern fits all molds). The water is temperature and flow controlled within the water bed layer.
In a second method which is basically the same as but there are no holes in water bed layer. Instead only the support skin layer is moved by actuators and the first set of pins is eliminated. The bridged pins may be best for this.
The pins can be as noted above can move through holes in the support skin but not through the water bed. Instead the pins flexibly push the sides of the water bed against the mold skin.
The following options can be included:
The pins can be single or bridged and can be in any number as required.
Optional walls can be added to support skin to assist in containment of water bag.
The water bag can be pressurized to assist in molding quality.
The water bag can be attached or detached from either or both mold skins to assist in molding logistics.
The water can circulate in the water bed and can be hot or cold.
Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departure from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
Claims (22)
1. A method of molding parts from a settable resin material comprising:
providing a first mold part and a second mold part which are arranged when brought together to define a cavity therebetween within which the resin can be injected at molding pressures and caused to set for forming the part in a molding process;
at least one of the mold parts comprising a pre-formed mold skin formed from a material which is flexible under the molding pressures;
providing a liquid in a chamber arranged to provide thermal contact with the mold skin for changing the temperature thereof during the molding process;
and providing a plurality of mechanical supporting elements for providing a supporting engagement with the mold skin at a plurality of spaced positions across the mold skin to prevent distortion of the mold skin during the molding, each mechanical supporting element including an engagement head portion and an adjustable portion such that actuation of the adjustment portions causes movement of the head portion relative to the mold skin to accommodate different mold skins.
providing a first mold part and a second mold part which are arranged when brought together to define a cavity therebetween within which the resin can be injected at molding pressures and caused to set for forming the part in a molding process;
at least one of the mold parts comprising a pre-formed mold skin formed from a material which is flexible under the molding pressures;
providing a liquid in a chamber arranged to provide thermal contact with the mold skin for changing the temperature thereof during the molding process;
and providing a plurality of mechanical supporting elements for providing a supporting engagement with the mold skin at a plurality of spaced positions across the mold skin to prevent distortion of the mold skin during the molding, each mechanical supporting element including an engagement head portion and an adjustable portion such that actuation of the adjustment portions causes movement of the head portion relative to the mold skin to accommodate different mold skins.
2. The method according to Claim 1 wherein the liquid is arranged in the chamber so as to be in contact with an outside surface of the mold skin.
3. The method according to Claim 1 wherein there is provided a flexible membrane between the liquid and an outside surface of the mold skin.
4. The method according to any preceding claim wherein the mechanical supporting elements each include at least a part extending through the chamber.
5. The method according to any preceding claim wherein the adjustment portion of the mechanical supporting elements is mounted in the chamber.
6. The method according to any one of Claims 1 to 4 wherein the adjustment portion of the mechanical supporting elements is mounted outside the chamber and each mechanical supporting element has a portion extending into the chamber.
7. The method according to Claim 6 wherein there is provided a seal on the portion at the location where it enters the chamber.
8. The method according to Claim 6 wherein there is provided a jacket on the part of the mechanical supporting elements within the chamber.
9. The method according to any preceding claim wherein the head portion comprises a separate element which is supported by two or more adjustment portions.
10. The method according to any preceding claim wherein the chamber is closed and is defined by a plurality of fixed walls leaving one side open and wherein the mold skin is located at the open side.
11. The method according to any preceding claim wherein the mold skin is removed with the part.
12. The method according to any preceding claim wherein mold skin sits on a flexible membrane covering the liquid in the chamber such that the mold skin is removed from the membrane leaving the membrane covering the chamber.
13. The method according to any preceding claim wherein there is provided a backing wall generally following the shape of the mold skin and wherein the liquid is contained between the mold skin and the backing wall.
14. The method according to Claim 13 wherein the liquid is contained in a flexible bag.
15. The method according to Claim 13 or 14 wherein the backing wall is flexible and wherein the mechanical supporting elements are arranged to engage the backing wall so as to transfer forces to the mold skin through the liquid.
16. The method according to Claim 13 or 14 wherein the backing wall has holes therein through which the mechanical supporting elements extend for applying forces to the mold skin.
17. The method according to Claim 16 wherein the mechanical supporting elements directly engage the outside surface of the mold skin through holes in the flexible bag.
18. The method according to Claim 16 wherein the flexible bag has inner and outer walls which have parts which are touched together at the mechanical supporting elements so that the mechanical supporting elements apply force directly to the outer surface of the mold skin.
19. The method according to Claim 1 wherein the inner and outer walls are connected at the parts.
20. The method according to Claim 1 wherein the mold skin is removed from the flexible bag with the part.
21. The method according to Claim 1 wherein the mold skin and the flexible bag and the backing wall are all removed with the part.
22. The method according to Claim 1 wherein the backing wall is formed from the same material as the mold skin and is matched generally in shape to the mold skin.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2487738 CA2487738A1 (en) | 2004-11-02 | 2004-11-02 | Molding thin wall parts in a closed mold |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2487738 CA2487738A1 (en) | 2004-11-02 | 2004-11-02 | Molding thin wall parts in a closed mold |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2487738A1 true CA2487738A1 (en) | 2006-05-02 |
Family
ID=36283123
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2487738 Abandoned CA2487738A1 (en) | 2004-11-02 | 2004-11-02 | Molding thin wall parts in a closed mold |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2487738A1 (en) |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2012107449A1 (en) * | 2011-02-07 | 2012-08-16 | Airbus Operations Gmbh | Setup device and method for manufacturing a fuselage barrel, made of a fiber composite material, for an aircraft |
| EP2399726A3 (en) * | 2010-06-24 | 2012-11-28 | Deutsches Zentrum für Luft- und Raumfahrt e. V. | Moulding tool for producing fibre compound components and method for producing fibre compound components with such a moulding tool |
| US20140175703A1 (en) * | 2012-11-06 | 2014-06-26 | Taylor Cable Products, Inc. | Apparatus for molding polymers and composite laminates |
| EP2899007A1 (en) * | 2014-01-28 | 2015-07-29 | Seuffer GmbH & Co. KG | Injection mould tool and casting installation with the injection mould tool |
| WO2015136157A1 (en) | 2014-03-14 | 2015-09-17 | Sironen Antti | Vacuum assisted resin infusion moulding method and mould |
| EP2977189A1 (en) * | 2014-07-21 | 2016-01-27 | The Boeing Company | Forming presses for forming joggled, stiffened composite structures |
| EP3254820A1 (en) * | 2016-06-09 | 2017-12-13 | Safran Aircraft Engines | Injection moulding device and method for manufacturing a workpiece |
| CN109732858A (en) * | 2018-12-24 | 2019-05-10 | 西安交通大学 | A kind of miniature compact multi-point flexibly mold |
-
2004
- 2004-11-02 CA CA 2487738 patent/CA2487738A1/en not_active Abandoned
Cited By (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2399726A3 (en) * | 2010-06-24 | 2012-11-28 | Deutsches Zentrum für Luft- und Raumfahrt e. V. | Moulding tool for producing fibre compound components and method for producing fibre compound components with such a moulding tool |
| US9067345B2 (en) | 2010-06-24 | 2015-06-30 | Deutches Zentrum fuer Luft- und Raumfahrt e.V. | Mold for manufacture of fiber composite parts and method of manufacture of fiber composite parts with such a mold |
| WO2012107449A1 (en) * | 2011-02-07 | 2012-08-16 | Airbus Operations Gmbh | Setup device and method for manufacturing a fuselage barrel, made of a fiber composite material, for an aircraft |
| US10124541B2 (en) | 2011-02-07 | 2018-11-13 | Airbus Operations Gmbh | Setup device and method for manufacturing a fuselage barrel for an aircraft |
| US9427898B2 (en) * | 2012-11-06 | 2016-08-30 | Taylor Cable Products, Inc. | Apparatus for molding polymers and composite laminates |
| US20140175703A1 (en) * | 2012-11-06 | 2014-06-26 | Taylor Cable Products, Inc. | Apparatus for molding polymers and composite laminates |
| EP2899007A1 (en) * | 2014-01-28 | 2015-07-29 | Seuffer GmbH & Co. KG | Injection mould tool and casting installation with the injection mould tool |
| EP3116709A4 (en) * | 2014-03-14 | 2017-11-22 | Sironen, Antti | Vacuum assisted resin infusion moulding method and mould |
| WO2015136157A1 (en) | 2014-03-14 | 2015-09-17 | Sironen Antti | Vacuum assisted resin infusion moulding method and mould |
| EP2977189A1 (en) * | 2014-07-21 | 2016-01-27 | The Boeing Company | Forming presses for forming joggled, stiffened composite structures |
| US9649817B2 (en) | 2014-07-21 | 2017-05-16 | The Boeing Company | Forming presses and methods for forming joggled, stiffened composite structures |
| EP3254820A1 (en) * | 2016-06-09 | 2017-12-13 | Safran Aircraft Engines | Injection moulding device and method for manufacturing a workpiece |
| FR3052383A1 (en) * | 2016-06-09 | 2017-12-15 | Snecma | INJECTION MOLDING DEVICE AND METHOD FOR MANUFACTURING A WORKPIECE |
| US10737422B2 (en) | 2016-06-09 | 2020-08-11 | Safran Aircraft Engines | Device and a method for fabricating a part by injection molding |
| CN109732858A (en) * | 2018-12-24 | 2019-05-10 | 西安交通大学 | A kind of miniature compact multi-point flexibly mold |
| CN109732858B (en) * | 2018-12-24 | 2020-02-18 | 西安交通大学 | Small dense multi-point flexible die |
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