WO2004098863B1 - Rapid thermoform pressure forming process and apparatus - Google Patents

Rapid thermoform pressure forming process and apparatus

Info

Publication number
WO2004098863B1
WO2004098863B1 PCT/CA2004/000675 CA2004000675W WO2004098863B1 WO 2004098863 B1 WO2004098863 B1 WO 2004098863B1 CA 2004000675 W CA2004000675 W CA 2004000675W WO 2004098863 B1 WO2004098863 B1 WO 2004098863B1
Authority
WO
WIPO (PCT)
Prior art keywords
air pressure
pressure chamber
mold
bladder
opening
Prior art date
Application number
PCT/CA2004/000675
Other languages
French (fr)
Other versions
WO2004098863A1 (en
Inventor
Grant David Kirchner
Original Assignee
Ortho Active Holdings Inc
Grant David Kirchner
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Ortho Active Holdings Inc, Grant David Kirchner filed Critical Ortho Active Holdings Inc
Publication of WO2004098863A1 publication Critical patent/WO2004098863A1/en
Publication of WO2004098863B1 publication Critical patent/WO2004098863B1/en

Links

Classifications

    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
    • 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
    • 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
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
    • B29C2043/3649—Inflatable bladders using gas or fluid and related details
    • 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
    • B29C33/20—Opening, closing or clamping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3041—Trim panels

Abstract

This invention relates to a novel apparatus and process for producing thermoplastic articles. In one aspect, the invention pertains to a process for manufacturing fiberglass products using a fiberglass material consisting of fiberglass strands commingled with heat-formable polypropylene strands. A molding apparatus comprising: (a) an air pressure chamber (4) with an open side; (b) a flange plate (6) fitted to the open side of the air pressure chamber, said flange plate having an opening therein for receiving a mold; (c) an upper bladder (8) associated with the flange plate and covering the opening; (d) a base pressure plate (18); (e) a mold (16) positioned on the base pressure plate; and (f) a locking mechanism for securing the air pressure chamber with the base pressure plate, and balanced air pressure in each chamber during molding.

Claims

29 AMENDED CLAIMS [received by the International Bureau 19 November 2004 (19.11.04); original claims 1 to 8 replaced by new claims 1 to 8; remaining claims unchanged (2 pages)] WHAT IS CLAIMED IS: 1. A molding apparatus comprising: (a) an air pressure chamber with an open side; (b) a flange plate fitted to the open side of the air pressure chamber, said 5 flange plate having an opening therein for receiving a mold; (c) a first upper bladder associated with the flange plate and covering the open side; (d) a base pressure plate; (e) a mold positioned on the base pressure plate;
10 (f) a locking mechanism for securing the air pressure chamber on the base pressure plate; (g) a second lower bladder positioned over the mold on the base pressure plate; and (h) an inlet/outlet port for enabling air to be first evacuated in order to pull 15 the first upper bladder away from the mold and then to be introduced into the air pressure chamber to force the first upper bladder against a thermoformable fibre reinforced composite material or other thermoplastic material positioned on the second lower bladder over the mold.
20 2. An apparatus as claimed in claim 1 including a retaining frame which holds the second lower bladder in place over the mold
3. An apparatus as claimed in claim 1 wherein the air pressure chamber is pivotally connected with the base pressure plate.
25 4. An apparatus as claimed in claim 1 wherein the mold is formed of a single piece or of sections which are assembled together.
5. An apparatus as claimed in claim 1 wherein the mold is porous. 30
6. An apparatus as claimed in claim 1 including an outlet for evacuating air from between the second lower bladder and the base pressure plate.
7. An apparatus as claimed in claim 1 wherein the air pressure chamber is in 35 the form of a hollow half cylinder.
8. An air pressure molding apparatus comprising: (a) a first air pressure chamber having an opening therein; 30
(b) a second air pressure chamber having an opening therein associated with the opening of the first air pressure chamber; (c) a first bladder associated with the opening of the first air pressure chamber; (d) a flange with an opening therein for receiving a mold located between the first and second air pressure chambers; (e) a mold associated with the flange; (f) a second bladder which fits over the mold and the flange; and (g) a third bladder associated with the opening of the second air pressure chamber and being on a side of the mold and flange opposite the second bladder.
9. An apparatus as claimed in claim 8 including a retaining frame which holds the second bladder, the first bladder and the flange on the first air pressure chamber.
10. An apparatus as claimed in claim 9 including a retaining frame which holds the third bladder on the second air pressure chamber.
11. An apparatus as claimed in claim 10 including flexible tubes for introducing air into or evacuating air from one or both of the first air pressure chamber and the second air pressure chamber and from the space between the first and second bladders. <
12. An apparatus as claimed in claim 8 including a thermoformable plastic or drape molded fibre reinforced composite placed over the second bladder vacuum fitted over the mold.
13. An apparatus as claimed in claim 12 including a heat source for heating a thermoformable plastic or drape molded fibre reinforced composite.
14. An apparatus as claimed in claim 8 wherein the first air pressure chamber and the second air pressure chamber are pivotally connected with one another and the first air pressure chamber and the second air pressure chamber can be closed and locked together.
15. An apparatus as claimed in claim 14 including a cylinder which pivotally closes the first air pressure chamber and the second air pressure chamber together.
PCT/CA2004/000675 2003-05-05 2004-05-05 Rapid thermoform pressure forming process and apparatus WO2004098863A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/429,035 2003-05-05
US10/429,035 US7326044B2 (en) 2003-05-05 2003-05-05 Rapid thermoform pressure forming process and apparatus

Publications (2)

Publication Number Publication Date
WO2004098863A1 WO2004098863A1 (en) 2004-11-18
WO2004098863B1 true WO2004098863B1 (en) 2005-01-20

Family

ID=33415999

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CA2004/000675 WO2004098863A1 (en) 2003-05-05 2004-05-05 Rapid thermoform pressure forming process and apparatus

Country Status (2)

Country Link
US (1) US7326044B2 (en)
WO (1) WO2004098863A1 (en)

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Also Published As

Publication number Publication date
WO2004098863A1 (en) 2004-11-18
US20040222562A1 (en) 2004-11-11
US7326044B2 (en) 2008-02-05

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