Abstract:
A device changes the shape of a die (22) used to compression mold a part. The device includes a sleeve (24) placed between the die and a charge to be molded. The sleeve (24) has an inner face (65) generally conforming to a face of the die, and an outer face (67) for molding a part.
Abstract:
A fabrication method of forming curved thermoplastic composite laminate parts with tailored and varying thickness in a continuous process and a curved thermoplastic laminate part obtained thereby. Automated equipment or hand lay-up are used to collate parts or components into, a multi-layer stack (226). Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Ply consolidation tooling (275, 284) contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.
Abstract:
A fabrication method of forming a thermoplastic composite laminate material with tailored and varying thickness in a continuous process. This process utilizes automated equipment or hand lay-up to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. The consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of 10 differing thickness from these multiple ply stacks.
Abstract:
An elongate thermoplastic composite member (20) is fabricated by a continuous molding process. A pre - consolidated thermoplastic laminate is softened by heating it to a temperature below its melting layup, and is fed substantially continuously through multiple sets of tool dies. The tool dies incrementally mold portions of softened laminate over a mandrel to form the laminate into a shape having a closed cross section.
Abstract:
Thermoplastic composite parts having integrated metal fittings (342, 343, 350) are manufactured using a continuous compression molding process. Automated equipment or hand lay-up are used to collate composite material plies and metal fittings into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Multiple lay-ups may be cut from each stack. The lay-ups (345) are placed in tooling containing part features and are continuously fed through a performing station where the lay-ups are preformed into the approximate shape of the finished part. Following pre-forming, the tooling is moved incrementally through a consolidation station where a compression press (354, 356) presses successive sections of the tooling to form a single integrated thermoplastic composite laminate part having integrated metal fittings, which may include areas of differing thickness.
Abstract:
A device changes the shape of a die used to compression mold a part. The device includes a sleeve placed between the die and a charge to be molded. The sleeve has an inner face generally conforming to a face of the die, and a outer face for molding a part.
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.
Abstract:
A fabrication method of forming curved thermoplastic composite laminate parts with tailored and varying thickness in a continuous process. Automated equipment or hand lay-up are used to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Ply consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.
Abstract:
A fabrication method of forming a thermoplastic composite laminate material (20) with tailored and varying thickness (tl, t2) in a continuous process. This process utilizes automated equipment or hand lay-up to collate parts or components into a multi-layer stack (74, 76). Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. The consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of 10 differing thickness from these multiple ply stacks.