US 11,858,179 B2Granted

Thermally expanding mandrel for cast components

AssigneeAmazon Technologies, Inc.

InventorsSteven McGinnis, Kader Chellabi, Prescott Gee Glynn, Adrian Timothy Wallace

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Abstract

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

Claims19

Dependent claims

A method of manufacturing a component, comprising:

forming a thermally expanding mandrel using an expanding material composition, wherein the expanding material composition comprises rubber particles and plaster, wherein the thermally expanding mandrel includes at least one surface feature that forms a corresponding surface feature on an interior surface of the component which is defined by a variation in a wall thickness of the component, and wherein the at least one surface feature of the thermally expanding mandrel includes at least one of a protrusion, bump, indentation, or dimple;
applying carbon fiber component material to the thermally expanding mandrel;
inserting the thermally expanding mandrel into a molding tool;
closing the molding tool;
applying heat to the thermally expanding mandrel and the molding tool during a period of time, wherein the thermally expanding mandrel expands and the carbon fiber component material cures to form the component including the corresponding surface feature on the interior surface of the component during the period of time;
opening the molding tool after the period of time;
removing the component from the molding tool;
and
washing out the thermally expanding mandrel from the component.

6 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/871,549Filed 15 Jan 2018
Published: US 2019/0217508 A118 Jul 2019
Granted: 2 Jan 2024
Term ends: Not estimatedThe source records don’t support an estimate.

Classification14 codes

B29C 33/52
With means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles: soluble or fusible
B29C 43/361
Moulds for making articles of definite length, i.e. discrete articles: with pressing members independently movable of the parts for opening or…
B29C 43/3642
Moulds for making articles of definite length, i.e. discrete articles: bags, bleeder sheets or cauls for isostatic pressing
B29C 70/44
For producing articles of definite length, i.e. discrete articles: using isostatic pressure, e.g. pressure difference-moulding, vacuum…