WO1991001871A1 - Moulding method and apparatus - Google Patents
Moulding method and apparatus Download PDFInfo
- Publication number
- WO1991001871A1 WO1991001871A1 PCT/GB1990/001149 GB9001149W WO9101871A1 WO 1991001871 A1 WO1991001871 A1 WO 1991001871A1 GB 9001149 W GB9001149 W GB 9001149W WO 9101871 A1 WO9101871 A1 WO 9101871A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mould tool
- mat
- mould
- perforated
- tool
- Prior art date
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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
- B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
- B29C51/004—Textile or other fibrous material made from plastics 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
- 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
- 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
- B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material
Abstract
The invention provides a method of moulding a reinforced structure for use in a subsequent moulding operation to form a moulded article, comprising the steps of heating a fibrous mat (10) formed from fibres held together by a thermoformable binder while between the parts (11) and (12) of a mould tool which parts (11) and (12) are pre-coated with a release agents; bringing the parts of the mould together using a vacuum with the mat (10) between them; allowing the mould tool, with the fibrous mat (10) therein to cool and removing the moulded reinforcing structure thus formed from the mould tool. The parts (11) and (12) of the mould are brought together by placing them in a vacuum forming table (14) and then evacuating the volume enclosed between the sheet (10) spanning the frame (15) and the lower part (13) of the table (14) when both are brought into contact.
Description
MOULDING METHOD AND APPARATUS
This invention relates to a method of moulding and to apparatus for carrying out the method.
In EP-A-0229441 there is described a method of moulding in which a reinforcement structure, for example of a glass fibre material, is placed between male and female mould tool parts which together define a cavity defining the shape of the moulded article to be produced, and a quantity of a thermosetting resin is then introduced into the mould tool cavity. The mould tool parts are then urged towards each other thereby to disperse the thermosetting resin throughout the reinforcement structure. The noted steps are carried out at an elevated temperature, for example 55°C, which is maintained after final closing of the mould tool parts together, for a period sufficient to effect curing of the thermosetting resin, after which period the moulded article formed between the mould tool parts can be removed from the mould tool for use or storage for later use.
With this known moulding method the quality of the moulded article produced is dependent upon the uniformity of the fibre reinforcement and the dispersion of the thermosetting
resin throughout the reinforcing structure, and since such dispersion occurs while the two parts of the mould tool are closed about the reinforcing structure, it can happen that complete and uniform dispersion does not always occur.
To overcome the problems detailed above, preformed dry reinforcements have been produced, for subsequent use in the moulding process. The preforms are generally fibrous in nature and have a self-supporting shape that approximates to the shape of the finished article or have a shape which allows them to conform with other preforms before moulding of the finished article. However, to date preform preparation has often been labour intensive and have involved costly tooling. Generally, the preforms are manufactured by mechanical press tooling. Furthermore, the processes used have not been very flexible, since different match parts have to be produced for each separate reinforcing structure, to enable the presses to mould the required shape.
The method of the present invention aims to overcome the disadvantages of the prior art by providing a flexible and inexpensive method of producing preformed reinforcement structures. The method does not involve elaborate apparatus and is flexible, the same apparatus being used for different mould tools to form a variety of different shaped preformed structures.
According to this invention there is provided a method of moulding a reinforcing structure for use in a subsequent moulding operation to form a moulded article, comprising heating a fibrous mat coated with a thermoformable binder while located between the parts of a mould tool, which parts are precoated with a release agent; bringing the parts of the mould tool together using a vacuum with the mat between them, allowing the mould tool with the fibrous mat therein to cool and removing the moulded reinforcing structure thus formed from the mould tool.
The present invention further provides a method of preforming a reinforcing structure for embodying in a subsequent moulding operation comprising the steps of; taking a fibrous mat embodying a thermoformable binder; raising the temperature of the mat to render the mat pliable; vacuum forming the mat in a mould tool defining the required shape; and allowing the mat to cool so that the mat becomes self-supporting with the shape defined by the mould tool before removing the mat from the mould tool.
The fibrous mat can be a continuous filament fibre mat or a woven fibre mat.
In a preferred method according to the invention the fibrous mat is initially cut to a template.
Preferably the mould tool is a two-part mould tool and
one part of the two-part mould tool defines the required shape of a first side of the mat and the other part defines the required shape of a second side of the mat.
The parts of the mould used in the method are preferably pre-coated with a PTFE release agent.
Preferably the mat is heated in the mould tool before vacuum forming the mat within said mould tool in an oven.
Preferably the vacuum forming is carried out by the steps of; placing the mat in the mould in a vacuum forming table, which vacuum forming table comprises a perforated table and a lid pivotally attached to said table, said lid comprising a frame and a flexible membrane spanning the area within the frame; bringing the lid and the table into contact; and evacuating the volume enclosed between the lid and the table such that pressure is applied to the mat to mould the mat to shape of the mould tool. Where the mould tool is a two-part mould tool, the flexible membrane is drawn down on to the mould tool when the volume between the lid and the table is evacuated such that the two-parts of the mould tool are drawn together to mould the mat to shape of the parts.
The mould tool used preferably comprises a perforated female mould part and a perforated male mould part.
Preferably the perforated female mould is flexible and the male mould ^ is made rigid by bonding it to a supporting structure.
The invention also provides moulding apparatus for use in carrying out a method as hereinbefore described, comprising a perforated mould tool in which the fibrous mat is received; means for heating said mould tool to pre-form the thermoformable material in the mould tool; and vacuum means adapted to receive the mould tool having the fibrous mat therein and operable without further heating to complete moulding of the fibrous mat in the mould tool to form the reinforcing structure.
Preferably the perforated mould tool comprises mutually conforming male and female parts adapted to receive the fibrous mat therebetween.
The mould tool is preferably of high thermal conductivity and is perforated with holes of up to 5mm diameter and separated from one another by a distance of up to 30 mm from centre to centre of adjacent holes. The mould tool can be formed by closing the tool around a prepared reinforcing structure.
Preferably the vacuum means of the apparatus comprises a perforated table, a vacuum chamber disposed beneath said perforated table, a frame pivotally connected to the perforated table, flexible material attached to said frame and spanning the area within said frame and means for evacuating the volume enclosed between the frames and the table when perforated they are brought into contact.
With the method of this invention there is formed a reinforcing structure which can be used in a subsequent moulding process during which the reinforcing structure is impregnated with resin, to form a high quality moulded article.
Therefore the invention provides a method of moulding a complete article which comprises initial steps as hereinbefore described and further comprises the steps of placing the moulded reinforcing stucture in a second mould tool of a plurality of parts; introducing thermosetting resin into the cavity defined by the second mould tool; urging the parts of the second mould tool together; curing the materials within the second mould tool; and removing the mould second tool parts after a time sufficient to allow curing of the thermosetting resin.
The invention will now be described by way of example with reference to the drawings, in which:-
Figure 1 shows a quantity of thermoformable material to be formed into a reinforcing structure by the method of the invention; and
Figures 2 to 6 show steps in the manufacture of a reinforcing structure by the method of the invention.
Referring to the drawings, there is shown a quantity of thermoformable material in the form of a sheet 10 of continuous filament fibre matting containing a thermoformable binder. A suitable thermoformable material is "UNIFILO U750". UNIFILO
U750 is a trade mark of Vetrotex International used for a random mat of unchopped continuous glass strands held together with a b_ ier having medium solubility in styrene and other monomers. UNIFILO U750 uses a binder of powder polyester of medium solubility in styrene. UNIFILO U750 is supplied worldwide and is supplied in the U.S.A. by Certainteed Corporation. A number of such different materials are commercially available.
Sheet 10 has been cut out according to a template (not shown) to be slightly oversized with respect to the reinforcing structure to be moulded.
The sheet 10 is located between the rigid male and flexible female part 11 of a two-part, perforated mould tool. The female part 11 of the mould tool is then bought together with the loaded male part and, if necessary, clamped or locked to retain the sheet 10 between the mould parts.
Both the male 12 and female 11 mould parts are perforated and therefore constitute perforated mould tooling. Both parts are pre-coated with a PTFE release agent to facilitate disassembly of the mould tool.
The perforated mould tooling 11, 12 is placed in an oven and heated to a temperature at which the binder of the thermoformable sheet 10 softens. For typical binders used with "UNIFILO U750" material, a minimum heating time to achieve a material temperature of 80 degrees Celsius is required. The
actual temperature and heating time are determined by the thermoformable binder and type of fibre used in the thermoformable sheet 10, the thickness of the thermoformable sheet 10; and the thermal conductivity of the mould parts 11 and 12.
The initial heating of the mould tooling pre-forms the thermoformable Sheet 10 to approximately the shape of the void between the male 12 and female 11 mould parts.
Whilst it is still hot, the mould tooling 11, 12 containing the thermoformable sheet 10 is removed from the oven and placed on the lower part 13 of a vacuum forming table 14. The hinged lid 15 of the vacuum forming table is then closed, thereby switching on the vacuum pump (not shown) of the vacuum forming table 14 by means of a switch 16, which sustains a minimum vaccuum of 25in Hg (635mm Hg) . The lower part 12 of the vacuum forming table is perforated. A vacuum chamber is located below the lower part 13 of the table 14. The vacuum pump evacuates the vacuum chamber.
The vacuum forming table operates without further heating of the mould tooling 11, 12 and thermoformable sheet 10 to draw the sheet 10 into close conformity with the void between the male 12 and female 11 mould parts.
After a predetermined time, approx. 30 sees, the vacuum pump is switched off and the mould tool is removed from the vacuum table and left to cool for between thirty seconds and a minute for most articles. After this time, the mould tool 11,
12 is removed from the vacuum forming table 14 and any protruding parts of the formed reinforcing structure 17 trimmed back to the joint between the male 12 and female 11 mould parts.
The male and female mould parts are then separated to permit removal of the formed reinforcing structure 17 which can subsequently be used in a moulding process, for example, as described in the above noted EP-A-0229441, in the manufacture of a finished moulded article.
The male 12 and female 11 parts of the mould tooling are preferably of high thermal conductivity to provide for rapid heating and cooling cycles. A suitable material for the mould parts has been found to be a polyester resin containing an aluminium filler. Mould tooling made from this material may itself be formed by closing the mould tool around an existing article which it is required to reproduce.
It has also been found that a suitable pattern of perforations of the mould tooling is to provide 5mm diameter circular holes having their centres spaced 30mm from one another in a regular pattern over the parts 11, 12 of the mould tooling. The male part of the mould tooling is preferably rigid. The desired rigidity can be achieved by bonding a lightweight box structure to the underside of the male part of the tooling.
Claims
1. A method of moulding a reinforcing structure for use in a subsequent moulding operation to form a moulded article, comprising heating a fibrous mat formed from fibres with a thermoformable binder dispersed therebetween while between the parts of a mould tool; bringing the parts of the mould together using a vacuum with the mat between them; allowing the mould tool with the fibrous mat therein to cool and removing the moulded reinforcing structure thus formed from the mould tool.
2. A method of preforming a reinforcing structure for embodying in a subsequent moulding operation comprising the steps of; taking a fibrous mat embodying a thermoformable binder; raising the temperature of the mat to render the mat pliable; vacuum forming the mat in a mould tool defining the required shape; and allowing the mat to cool so that the mat becomes self-supporting with the shape defined by the mould tool before removing the mat from the mould tool.
3. A method as claimed in Claim 2 wherein the mould tool is a two-part mould tool.
4. A method as claimed in Claim 3 wherein one part of the two-part mould tool defines the required shape of a first side of the mat and the other part defines the required shape of a second side of the mat.
5. A method as claimed in any one of claims 1 to 4, in which the fibrous mat is a continuous filament fibre mat.
6. A method as clair.ed in any one of claims 1 to 4, in which the fibrous mat is a woven fibre mat.
7. A method as claimed in any one of the preceding claims wherein the mould tool is perforated.
8. A method as claimed in any one of the preceding claims wherein the mat is heated in the mould tool before vacuum forming the mat within said mould tool.
9. A method as claimed in Claim 8 wherein the mat is heated in the mould tool in an oven.
10. A method as claimed in any one of the preceding claims wherein the vacuum forming is carried out by the steps of; placing the mat in the mould in a vacuum forming table, which vacuum forming table comprises a perforated table and a lid pivotally ai_i_ached to said table, said lid comprising a frame and a flexible membrane spanning the area within the frame; bringing the lid and the table into contact; and evacuating the volume enclosed between the lid and the table such that pressure is applied to the mat to mould the mat to shape of the mould tool.
11. A method as claimed in Claim 10 wherein the mould tool is a two-part mould tool and the flexible membrane is drawn down to the mould tool when the volume between the lid and the table is evacuated such that the two-parts of the mould tool are drawn together to mould the mat to shape of the parts.
12. A method as claimed in any one of the preceding claims, in which the fibrous mat is initially cut to a template.
13. A method as claimed in any one of the preceding claims in which the mould tool is pre-coated with a release agent.
14. A method a≤ claimed in Claim 13 wherein the release agent is a PTFE release agent.
15. A method according to any one of the preceding claims, wherein the mould tool used comprises a perforated female mould part and a perforated male mould part.
16. A method as claimed in Claim 15 wherein the perforated female mould is flexible and the male mould is made rigid by bonding it to a supporting structure.
17. A method of moulding an article comprising initial steps according to any one of the preceding claims and further comprising the steps of placing the moulded reinforcing structure in a second mou.": tool of a plurality of parts; introducing thermosetting resin into the cavity defined by the second mould tool; urging the parts of the second mould tool together; curing the material within the second mould tool; and removing the mould tool parts after a time sufficient to allow curing of the thermosetting resin.
18. Moulding apparatus for use in carrying out a method as claimed in Claim 1 or Claim 2, comprising a perforated mould tool in which the fibrous mat is received; means for heating said mould tool to pre-form the thermoformable material in the mould tool; and vacuum means adapt 1 to receive the mould tool having the fibrous mat therein and operable without further heating to complete moulding of the fibrous mat in the mould tool to form the reinforcing structure.
19. Apparatus according to Claim 18 wherein the vacuum means comprises a perforated table, a vacuum chamber disposed beneath said perforated table, a frame pivotally connected to the perforated table, flexible material attached to said frame and spanning the area within said frame and means for evacuating the volume enclosed between the frame and the perforated table when they are brought into contact.
20. Moulding apparatus according to Claim 18 or Claim 19, wherein the perforated mould tool comprises mutually conforming male and female parts adapted to receive the fibrous mat therebetween.
21. Apparatus according to any one of claims 10 to 12, wherein the mould tool is of high thermal conductivity.
22. Apparatus according to any one of Claims 10 to 13, wherein the mould tool is perforated with holes of up to 5mm diameter and separated from one another by a distance of up to 30mm from centre to centre of adjacent holes.
23. Apparatus according to any one of Claims 10 to 14 wherein the mould tool is formed by closing the tool around a prepared reinforcing structure.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9201248A GB2254037B (en) | 1989-07-27 | 1992-01-15 | Moulding method and apparatus |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8917142.5 | 1989-07-27 | ||
| GB898917142A GB8917142D0 (en) | 1989-07-27 | 1989-07-27 | Moulding method and apparatus |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO1991001871A1 true WO1991001871A1 (en) | 1991-02-21 |
Family
ID=10660697
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/GB1990/001149 WO1991001871A1 (en) | 1989-07-27 | 1990-07-25 | Moulding method and apparatus |
Country Status (3)
| Country | Link |
|---|---|
| GB (1) | GB8917142D0 (en) |
| MY (1) | MY107064A (en) |
| WO (1) | WO1991001871A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1999048670A1 (en) * | 1998-03-26 | 1999-09-30 | Lear Corporation | Method and apparatus for molding headliners |
Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB940407A (en) * | 1961-03-29 | 1963-10-30 | Ford Motor Co | Method of shaping a sheet material containing a heat deformable component |
| GB1024582A (en) * | 1961-07-05 | 1966-03-30 | Rodgers William | A method of manufacturing a synthetic resin moulding reinforced with fibrous material |
| US3559236A (en) * | 1969-12-02 | 1971-02-02 | Glass Reinforced Engineered Ma | Apparatus for molding plastic |
| DE1958110A1 (en) * | 1969-11-19 | 1971-05-27 | Metallgiesserei Und Schilderfa | Preformed vulcanised car floor mat |
| FR2258136A1 (en) * | 1974-01-22 | 1975-08-18 | Fontanille Jean Claude | Hot forming part of a garment containing synthetic material - by forcing into a mould using membrane controlled by fluid pressure |
| FR2567807A1 (en) * | 1984-07-20 | 1986-01-24 | Bronzavia Sa | Process for the production of components made from composite materials and device for the implementation of this process and components obtained by this process |
| US4608220A (en) * | 1984-12-20 | 1986-08-26 | The Boeing Company | Method of forming composite material articles |
| EP0229441A2 (en) * | 1986-01-10 | 1987-07-22 | Group Lotus Plc | Method of moulding an article |
| EP0243617A2 (en) * | 1986-05-02 | 1987-11-04 | AlliedSignal Inc. | Method for the manufacture of fiber reinforced structural composites |
| US4842787A (en) * | 1986-12-22 | 1989-06-27 | Xerkon, Inc. | High speed process for production of oriented structural yarn/polymer matrix composite structural parts |
-
1989
- 1989-07-27 GB GB898917142A patent/GB8917142D0/en active Pending
-
1990
- 1990-07-25 WO PCT/GB1990/001149 patent/WO1991001871A1/en unknown
- 1990-07-26 MY MYPI90001258A patent/MY107064A/en unknown
Patent Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB940407A (en) * | 1961-03-29 | 1963-10-30 | Ford Motor Co | Method of shaping a sheet material containing a heat deformable component |
| GB1024582A (en) * | 1961-07-05 | 1966-03-30 | Rodgers William | A method of manufacturing a synthetic resin moulding reinforced with fibrous material |
| DE1958110A1 (en) * | 1969-11-19 | 1971-05-27 | Metallgiesserei Und Schilderfa | Preformed vulcanised car floor mat |
| US3559236A (en) * | 1969-12-02 | 1971-02-02 | Glass Reinforced Engineered Ma | Apparatus for molding plastic |
| FR2258136A1 (en) * | 1974-01-22 | 1975-08-18 | Fontanille Jean Claude | Hot forming part of a garment containing synthetic material - by forcing into a mould using membrane controlled by fluid pressure |
| FR2567807A1 (en) * | 1984-07-20 | 1986-01-24 | Bronzavia Sa | Process for the production of components made from composite materials and device for the implementation of this process and components obtained by this process |
| US4608220A (en) * | 1984-12-20 | 1986-08-26 | The Boeing Company | Method of forming composite material articles |
| EP0229441A2 (en) * | 1986-01-10 | 1987-07-22 | Group Lotus Plc | Method of moulding an article |
| EP0243617A2 (en) * | 1986-05-02 | 1987-11-04 | AlliedSignal Inc. | Method for the manufacture of fiber reinforced structural composites |
| US4842787A (en) * | 1986-12-22 | 1989-06-27 | Xerkon, Inc. | High speed process for production of oriented structural yarn/polymer matrix composite structural parts |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6146578A (en) * | 1997-10-09 | 2000-11-14 | Lear Corporation | Method for molding headliners |
| WO1999048670A1 (en) * | 1998-03-26 | 1999-09-30 | Lear Corporation | Method and apparatus for molding headliners |
Also Published As
| Publication number | Publication date |
|---|---|
| MY107064A (en) | 1995-09-30 |
| GB8917142D0 (en) | 1989-09-13 |
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