CA2487697A1 - Molding thin wall parts in a closed mold - Google Patents
Molding thin wall parts in a closed mold Download PDFInfo
- Publication number
- CA2487697A1 CA2487697A1 CA002487697A CA2487697A CA2487697A1 CA 2487697 A1 CA2487697 A1 CA 2487697A1 CA 002487697 A CA002487697 A CA 002487697A CA 2487697 A CA2487697 A CA 2487697A CA 2487697 A1 CA2487697 A1 CA 2487697A1
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- CA
- Canada
- Prior art keywords
- mold
- skin
- mold skin
- supporting
- head portion
- 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
-
- 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
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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
- B29C33/307—Mould plates mounted on frames; Mounting the mould plates; Frame constructions therefor
-
- 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
-
- 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
-
- 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
-
- 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
-
- 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
- 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
- B29C51/087—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts with at least one of the mould parts comprising independently movable sections
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 is 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 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.
This invention relates to a method of molding thin wall part in a closed mold wherein one or both of the mold parts is 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 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 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;
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, at least some of the mechanical supporting elements each including an engagement head portion and a plurality of adjustable support portions engaging and supporting the engagement head at a required location 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 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 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;
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, at least some of the mechanical supporting elements each including an engagement head portion and a plurality of adjustable support portions engaging and supporting the engagement head at a required location 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 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.
5 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.
In one arrangement, the engagement head portions directly engage an outside surface of the mold skin.
In a preferred but not essential option, the mold skin is removed with the part for cooling while the mold elements are used with another mold skin for molding another part.
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.
In one arrangement, the engagement head portions directly engage an outside surface of the mold skin.
In a preferred but not essential option, the mold skin is removed with the part for cooling while the mold elements are used with another mold skin for molding another part.
In one arrangement, the engagement head portion has a planar face for supporting the mold skin.
Alternatively or at other locations on the mold skin, the engagement head portion has a face which is non-planar and is shaped to match an associated portion of the outside surface of the mold skin for supporting the mold skin.
In another option, at least one of the head portions is supported by more than two adjustable support portions.
Preferably the adjustment portions comprise elongate members each movable along its axis.
The axes may be parallel or arranged at an angle to one another to provide support from two different directions.
Preferably each adjustment portion is pivotally connected to the engagement head portion to allow the head to move to a required angle The adjustment portions may include numerically controlled linear actuators for moving the head portion to the required location. Alternatively they may be manually adjustable simply by sliding through a sleeve or by threaded adjustment using a nut.
Preferably each engagement head portion is removable from its supporting adjustable support portions. In this way a simple array of supporting pins can be used with different heads which are specifically designed and arranged to provide support for different shapes.
According to a second 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;
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;
the mechanical supporting elements each including an engagement head portion and at least one adjustable support portion engaging and supporting the engagement head at a required location at the outside surface of the mold skin;
and actuating at least some of the adjustable support portions to move the head portions thereof to increase compression on the resin in the cavity after the resin is injected.
Preferably the increased compression acts to expel air and/or resin from the cavity thus acting to increase a proportion of a reinforcing fibers layer relative to resin content of the part when molded.
Preferably the adjustable support portions are returned to an initial position, after being actuated to increase the compression, for injection of another part.
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.
In the drawings like characters of reference indicate corresponding 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 frame 15 which may be formed from a base wall 16 and upstanding side walls 17 The peripheral edge 18 of the frame carries a bottom 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. The mold skin can be clamped to the edges of the frame or may be simply a loose fit on the frame. In the top mold element which is inverted, a clamped mold skin will be used in most cases.
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 5 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 10 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.
The adjustable portions form an array of pins or shafts 25 which is preferably equidistantly spaced in rows and columns longitudinally of the part and transversely of the part such that the pins can be selected and used to support different arrangements of mold skin. The use of equidistant arrays allows the system to be used and designed for various different mold shapes by selecting suitable ones of the pins to support single heads, extended heads or bars carried by two pins and/or multiple heads or plates carried by three or more pins.
However the array my not be equidistant and only selected locations of pins may be provided for specific designs.
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 guide 27 in the base 15 to maintain the shaft moving along its axis. 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 shafts can be determined.
The mold skin is supported by a plurality of heads 24 each in the form of a plate having an upper surface 30 arranged to engage on a portion of the outside surface of the mold skin. Some of the heads 24 are mounted on only one shaft 25.
some are mounted on two shafts and some are mounted on more than two shafts.
Thus selected ones of the shafts can carry a single head on the form of a flat pad.
Some of the shafts carry a bar extending longitudinally of the mold skin and may be supported only at its ends on two shafts or may be mounted on a longitudinal row of the shafts. Some of the shafts carry a rectangular plate which bridges shafts both longitudinally and transversely so that such a plate may be supported by four shafts arranged at the corners of the plates. Other shafts may be arranged in a triangle.
It will be appreciated that the array of shafts can be used to support a design of heads which is selected for best supporting the mold skin depending on the shape of the mold skin and its tendency to flex. In many cases all of the heads will be of the multiple support type since this reduces the complexity of the adjustments action. Each head is pivotal relative to the end of the shafts on which it is carried 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.
In Figure 1 is shown three such mechanical supporting elements on each side of a center line of the mold skin. In the arrangement shown, none comprises an individual head supported on an individual shaft. Thus there are four rectangular plates 24A to 24D each supported on four corner shafts (only two of which are visible but the others are spaced longitudinally of the mold. Two plates or bars 24E and 24F are arranged as longitudinal bars extending along the mold longitudinally and supported on two longitudinally space pins. It will be appreciated that the bars may be transverse and be mounted on two transversely spaced pins.
In Figure 2 there is shown an alternative arrangement wherein the support for the mold skin is effectively formed in two halves with each half carried on four or more shafts.
Each shaft is pivotally connected to each head 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.
In the embodiment shown the complex shape carried by the heads 24E and 24F 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.
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 supports since the mold skin simply sits loosely on the supports 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 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 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 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.
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 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 controlled machine to actuate the movement of the adjustment portions so that the heads are moved to the required locations. In certain circumstances different heads can 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, 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.
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.
Alternatively or at other locations on the mold skin, the engagement head portion has a face which is non-planar and is shaped to match an associated portion of the outside surface of the mold skin for supporting the mold skin.
In another option, at least one of the head portions is supported by more than two adjustable support portions.
Preferably the adjustment portions comprise elongate members each movable along its axis.
The axes may be parallel or arranged at an angle to one another to provide support from two different directions.
Preferably each adjustment portion is pivotally connected to the engagement head portion to allow the head to move to a required angle The adjustment portions may include numerically controlled linear actuators for moving the head portion to the required location. Alternatively they may be manually adjustable simply by sliding through a sleeve or by threaded adjustment using a nut.
Preferably each engagement head portion is removable from its supporting adjustable support portions. In this way a simple array of supporting pins can be used with different heads which are specifically designed and arranged to provide support for different shapes.
According to a second 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;
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;
the mechanical supporting elements each including an engagement head portion and at least one adjustable support portion engaging and supporting the engagement head at a required location at the outside surface of the mold skin;
and actuating at least some of the adjustable support portions to move the head portions thereof to increase compression on the resin in the cavity after the resin is injected.
Preferably the increased compression acts to expel air and/or resin from the cavity thus acting to increase a proportion of a reinforcing fibers layer relative to resin content of the part when molded.
Preferably the adjustable support portions are returned to an initial position, after being actuated to increase the compression, for injection of another part.
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.
In the drawings like characters of reference indicate corresponding 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 frame 15 which may be formed from a base wall 16 and upstanding side walls 17 The peripheral edge 18 of the frame carries a bottom 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. The mold skin can be clamped to the edges of the frame or may be simply a loose fit on the frame. In the top mold element which is inverted, a clamped mold skin will be used in most cases.
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 5 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 10 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.
The adjustable portions form an array of pins or shafts 25 which is preferably equidistantly spaced in rows and columns longitudinally of the part and transversely of the part such that the pins can be selected and used to support different arrangements of mold skin. The use of equidistant arrays allows the system to be used and designed for various different mold shapes by selecting suitable ones of the pins to support single heads, extended heads or bars carried by two pins and/or multiple heads or plates carried by three or more pins.
However the array my not be equidistant and only selected locations of pins may be provided for specific designs.
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 guide 27 in the base 15 to maintain the shaft moving along its axis. 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 shafts can be determined.
The mold skin is supported by a plurality of heads 24 each in the form of a plate having an upper surface 30 arranged to engage on a portion of the outside surface of the mold skin. Some of the heads 24 are mounted on only one shaft 25.
some are mounted on two shafts and some are mounted on more than two shafts.
Thus selected ones of the shafts can carry a single head on the form of a flat pad.
Some of the shafts carry a bar extending longitudinally of the mold skin and may be supported only at its ends on two shafts or may be mounted on a longitudinal row of the shafts. Some of the shafts carry a rectangular plate which bridges shafts both longitudinally and transversely so that such a plate may be supported by four shafts arranged at the corners of the plates. Other shafts may be arranged in a triangle.
It will be appreciated that the array of shafts can be used to support a design of heads which is selected for best supporting the mold skin depending on the shape of the mold skin and its tendency to flex. In many cases all of the heads will be of the multiple support type since this reduces the complexity of the adjustments action. Each head is pivotal relative to the end of the shafts on which it is carried 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.
In Figure 1 is shown three such mechanical supporting elements on each side of a center line of the mold skin. In the arrangement shown, none comprises an individual head supported on an individual shaft. Thus there are four rectangular plates 24A to 24D each supported on four corner shafts (only two of which are visible but the others are spaced longitudinally of the mold. Two plates or bars 24E and 24F are arranged as longitudinal bars extending along the mold longitudinally and supported on two longitudinally space pins. It will be appreciated that the bars may be transverse and be mounted on two transversely spaced pins.
In Figure 2 there is shown an alternative arrangement wherein the support for the mold skin is effectively formed in two halves with each half carried on four or more shafts.
Each shaft is pivotally connected to each head 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.
In the embodiment shown the complex shape carried by the heads 24E and 24F 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.
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 supports since the mold skin simply sits loosely on the supports 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 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 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 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.
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 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 controlled machine to actuate the movement of the adjustment portions so that the heads are moved to the required locations. In certain circumstances different heads can 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, 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.
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 (27)
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;
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, at least some of the mechanical supporting elements each including an engagement head portion and a plurality of adjustable support portions engaging and supporting the engagement head at a required location 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;
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, at least some of the mechanical supporting elements each including an engagement head portion and a plurality of adjustable support portions engaging and supporting the engagement head at a required location 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 engagement head portions directly engage an outside surface of the mold skin.
3. The method according to any preceding claim wherein the mold skin is removed with the part.
4. The method according to any preceding claim wherein the engagement head portion has a planar face for supporting the mold skin.
5. The method according to any preceding claim wherein the engagement head portion has a face which is non-planar and is shaped to approximately match an associated portion of the outside surface of the mold skin for supporting the mold skin.
6. The method according to any preceding claim wherein at least one of the head portions is supported by more than two adjustable support portions.
7. The method according to any preceding claim wherein the adjustment portions comprises elongate members each movable along its axis.
8. The method according to Claim 7 wherein the axes are parallel.
9. The method according to Claim 7 wherein the axes are arranged at an angle to one another to provide support from two different directions.
10. The method according to any preceding claim wherein each adjustment portion is pivotal mounted on the engagement head portion.
11. The method according to any preceding claim wherein the adjustment portions include numerically (PLC or computer) controlled linear actuators for moving the head portion to the required location.
12. The method according to any preceding claim wherein each engagement head portion is removable from its supporting adjustable support portions.
13. 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;
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;
the mechanical supporting elements each including an engagement head portion and at least one adjustable support portion engaging and supporting the engagement head at a required location at the outside surface of the mold skin;
and actuating at least some of the adjustable support portions to move the head portions thereof to increase compression on the resin in the cavity after the resin is injected.
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;
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;
the mechanical supporting elements each including an engagement head portion and at least one adjustable support portion engaging and supporting the engagement head at a required location at the outside surface of the mold skin;
and actuating at least some of the adjustable support portions to move the head portions thereof to increase compression on the resin in the cavity after the resin is injected.
14. The method according to Claim 14 wherein the increased compression acts to expel air and/or resin from the cavity.
15. The method according to Claim 14 wherein the increased compression acts to expel resin from the cavity to increase a proportion of a reinforcing fibers layer relative to resin content of the part when molded.
16. The method according to any one of Claims 14 to 15 wherein the adjustable support portions are returned to an initial position, after being actuated to increase the compression, for injection of another part.
17. The method according to any one of Claims 14 to 16 wherein the engagement head portions directly engage an outside surface of the mold skin.
18. The method according to any one of Claims 14 to 18 wherein the mold skin is removed with the part.
19. The method according to any one of Claims 14 to 18 wherein the engagement head portion has a planar face for supporting the mold skin.
20. The method according to any one of Claims 14 to 19 wherein the engagement head portion has a face which is non-planar and is shaped to match an associated portion of the outside surface of the mold skin for supporting the mold skin.
21. The method according to any one of Claims 14 to 20 wherein at least one of the head portions is supported by more than two adjustable support portions.
22. The method according to any one of Claims 14 to 21 wherein the adjustment portions comprises elongate members each movable along its axis.
23. The method according to Claim 22 wherein the axes are parallel.
24. The method according to Claim 22 wherein the axes are arranged at an angle to one another to provide support from two different directions.
25. The method according to any one of Claims 14 to 24 wherein each adjustment portion is pivotally mounted on the engagement head portion.
26. The method according to any one of Claims 14 to 25 wherein the adjustment portions include numerically (PLC or computer) controlled linear actuators for moving the head portion to the required location.
27. The method according to any one of Claims 14 to 26 wherein each engagement head portion is removable from its supporting adjustable support portions.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002487697A CA2487697A1 (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 |
|---|---|---|---|
| CA002487697A CA2487697A1 (en) | 2004-11-02 | 2004-11-02 | Molding thin wall parts in a closed mold |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2487697A1 true CA2487697A1 (en) | 2006-05-02 |
Family
ID=36283120
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002487697A Abandoned CA2487697A1 (en) | 2004-11-02 | 2004-11-02 | Molding thin wall parts in a closed mold |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2487697A1 (en) |
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