Pressurized molding of composite parts
AssigneeHexcel Corporation
InventorAlfonso Lopez
Life of this patent
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Abstract
Apparatus and methods for molding composite bodies into composite parts using pressure. A lower inflexible mold is combined with an elastic upper mold layer to form a molding cavity in which the composite body to be molded is placed. An elastic pressure layer is used in combination with the upper mold layer to form a pressure chamber. A flexible expansion control layer is used to limit the increase in surface area of the pressure layer during pressurization. A perimeter retention lock is provided to prevent the perimeters of the elastic and flexible layers from moving inward or away from the lower mold during application of pressure to the pressure chamber.
Claims15
An apparatus for molding a composite body into a composite part, said apparatus comprising:
- a lower mold comprising an inflexible mold surface upon which said composite body is placed;
- an elastic upper mold layer comprising a mold surface that covers said lower mold surface to provide a molding cavity in which said composite body is located during molding of said composite body into said composite part, said upper mold layer having a perimeter;
- an elastic pressure layer located above said upper mold layer, said pressure layer having a perimeter that is sealed to said upper mold layer to provide a pressure chamber located between said upper mold layer and said pressure layer;
- a pressurization port to allow application of pressure to said pressure chamber in order to increase the volume of said pressure chamber, wherein the increase in volume of said pressure chamber increases the surface area of said pressure layer;
- a flexible expansion control layer located above said pressure layer to limit the increase in surface area of said pressure layer;
- and
- a perimeter retention lock located around the perimeters of said upper mold layer, said pressure layer and said expansion control layer, to prevent said perimeters from moving inward or away from said lower mold surface during application of pressure to said pressure chamber.
A method for molding a composite body into a composite part comprising the steps of:
- A) providing an apparatus comprising:
- a lower mold comprising an inflexible mold surface upon which said composite body is placed;
- an elastic upper mold layer comprising a mold surface that covers said lower mold surface to provide a molding cavity in which said composite body is located during molding of said composite body into said composite part, said upper mold layer having a perimeter;
- an elastic pressure layer located above said upper mold, said pressure layer having a perimeter that is sealed to said upper mold layer to provide a pressure chamber located between said upper mold layer and said pressure layer;
- a pressurization port to allow application of pressure to said pressure chamber in order to increase the volume of said pressure chamber, wherein the increase in volume of said pressure chamber increases the surface area of said pressure layer;
- a flexible expansion control layer located above said pressure layer to limit the increase in surface area of said pressure layer;
- a perimeter retention lock located around the perimeters of said upper mold layer, said pressure layer and said expansion control layer, to prevent said perimeters from moving inward or away from said lower mold surface during application of pressure to said pressure chamber;
- B) locating a composite body within said molding cavity;
- and
- C) applying pressure to said pressure chamber through said pressurization port to provide an increase in the volume of said pressure chamber.
Dependencies are inferred from the claim text.