公开(公告)号：US20190217510A1

公开(公告)日：2019-07-18

申请号：US15871517

申请日：2018-01-15

Applicant: Amazon Technologies, Inc.

Inventor： Steven McGinnis ,  Prescott Gee Glynn ,  Kader Chellabi ,  Adrian Timothy Wallace ,  Ricky Dean Welsh

IPC: B29C44/58 ,  B29C44/34 ,  B29C44/42 ,  B29C33/48 ,  B29C33/50 ,  B29D99/00

CPC classification number: B29C44/583 ,  B29C33/485 ,  B29C33/505 ,  B29C44/355 ,  B29C44/42 ,  B29D99/0025 ,  B29L2031/3085

Abstract: Lightweight and strong components may be manufactured using foam material compositions and resin coating materials by the processes described herein. One or more mandrels and/or a molding tool may be coated with resin coatings, the one or more mandrels may be inserted into the molding tool, and a foam material composition may be injected into the molding tool. After closing the molding tool, the foam material composition may expand and cure to form a component, and heat may be applied to cure the resin coatings into skins. For example, an external skin may be formed by the resin coatings on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed by the resin coatings on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

公开(公告)号：US11052583B2

公开(公告)日：2021-07-06

申请号：US15871517

申请日：2018-01-15

Applicant: Amazon Technologies, Inc.

Inventor： Steven McGinnis ,  Prescott Gee Glynn ,  Kader Chellabi ,  Adrian Timothy Wallace ,  Ricky Dean Welsh

IPC: B29C44/58 ,  B29C44/34 ,  B29C44/42 ,  B29C33/50 ,  B29D99/00 ,  B29C33/38 ,  B29L31/30 ,  B29C33/48

Abstract: Lightweight and strong components may be manufactured using foam material compositions and resin coating materials by the processes described herein. One or more mandrels and/or a molding tool may be coated with resin coatings, the one or more mandrels may be inserted into the molding tool, and a foam material composition may be injected into the molding tool. After closing the molding tool, the foam material composition may expand and cure to form a component, and heat may be applied to cure the resin coatings into skins. For example, an external skin may be formed by the resin coatings on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed by the resin coatings on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

公开(公告)号：US11858179B2

公开(公告)日：2024-01-02

申请号：US15871549

申请日：2018-01-15

Applicant: Amazon Technologies, Inc.

Inventor： Steven McGinnis ,  Kader Chellabi ,  Prescott Gee Glynn ,  Adrian Timothy Wallace

IPC: B29C33/52 ,  B29C70/44 ,  B29C43/36 ,  B29C33/54 ,  B29C33/42 ,  B33Y80/00 ,  B29C43/32 ,  B29L31/30

CPC classification number: B29C33/52 ,  B29C43/361 ,  B29C43/3642 ,  B29C70/44 ,  B29C33/42 ,  B29C33/54 ,  B29C2043/3261 ,  B29C2043/3668 ,  B29L2031/3085 ,  B33Y80/00

Abstract: Lightweight and strong components having any desired shape, form, or geometry may be manufactured using thermally expanding mandrels by the processes described herein. A thermally expanding mandrel may be formed from an expanding material composition including thermally expanding particles, e.g., micronized rubber particles, and water-soluble binder material, e.g., gypsum plaster. Component material may be applied to the mandrel, and the mandrel may be inserted into a molding tool. Upon application of heat to the mandrel, the mandrel may expand, and compress and cure the component material into a component within the molding tool. Following formation of the component, the mandrel may be washed out of the component, e.g., using pressurized water, and the expanding material composition may be recycled and/or reused.

公开(公告)号：US11731325B2

公开(公告)日：2023-08-22

申请号：US15871521

申请日：2018-01-15

Applicant: Amazon Technologies, Inc.

Inventor： Steven McGinnis ,  Prescott Gee Glynn ,  Kader Chellabi ,  Adrian Timothy Wallace ,  Ricky Dean Welsh

IPC: B29C44/42 ,  B29C44/58 ,  B29C44/34 ,  B29C33/50 ,  B29D99/00 ,  B29C33/48 ,  B29L31/30 ,  B29C33/42

CPC classification number: B29C44/583 ,  B29C33/485 ,  B29C33/505 ,  B29C44/355 ,  B29C44/42 ,  B29D99/0025 ,  B29C33/424 ,  B29L2031/3085

Abstract: Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

公开(公告)号：US20190217511A1

公开(公告)日：2019-07-18

申请号：US15871521

申请日：2018-01-15

Applicant: Amazon Technologies, Inc.

Inventor： Steven McGinnis ,  Prescott Gee Glynn ,  Kader Chellabi ,  Adrian Timothy Wallace ,  Ricky Dean Welsh

IPC: B29C44/58 ,  B29C44/34 ,  B29C44/42 ,  B29C33/48 ,  B29C33/50 ,  B29D99/00

CPC classification number: B29C44/583 ,  B29C33/485 ,  B29C33/505 ,  B29C44/355 ,  B29C44/42 ,  B29D99/0025 ,  B29L2031/3085

Abstract: Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

公开(公告)号：US20190217508A1

公开(公告)日：2019-07-18

申请号：US15871549

申请日：2018-01-15

Applicant: Amazon Technologies, Inc.

Inventor： Steven McGinnis ,  Kader Chellabi ,  Prescott Gee Glynn ,  Adrian Timothy Wallace

IPC: B29C33/52 ,  B29C33/54 ,  B29C70/44 ,  B29C43/36

CPC classification number: B29C33/52 ,  B29C33/42 ,  B29C33/54 ,  B29C43/361 ,  B29C70/44 ,  B29C2043/3261 ,  B29C2043/3668 ,  B33Y80/00

Abstract: Lightweight and strong components having any desired shape, form, or geometry may be manufactured using thermally expanding mandrels by the processes described herein. A thermally expanding mandrel may be formed from an expanding material composition including thermally expanding particles, e.g., micronized rubber particles, and water-soluble binder material, e.g., gypsum plaster. Component material may be applied to the mandrel, and the mandrel may be inserted into a molding tool. Upon application of heat to the mandrel, the mandrel may expand, and compress and cure the component material into a component within the molding tool. Following formation of the component, the mandrel may be washed out of the component, e.g., using pressurized water, and the expanding material composition may be recycled and/or reused.