US 5,182,060 A · Continuous forming of composites

Abstract

A continuous forming method is provided here whereby long composite structural shapes such as "Z", "HAT", "L", etc. can be formed economically with relatively small equipment. First, a lay-up is made from unidirectional tape or woven cloth, then the material is heated to accommodate softening of resin, then pulled through a set of rollers, then through a matched metal die and a rapidly reciprocating punch that facilitates to form the final shape. As the material is pulled through the area of match metal die and punch, it is cooled down by the heat sink of the die and punch, or any other means, so when the part exits the die and punch area, it is sufficiently cooled down to retain the desired shape. The rapidly reciprocating punch permits the part to be pulled continuously, thereby enabling it to produce a long part very economically.

Claims6

Dependent claims

A method for shaping a fiber reinforced thermoplastic resin composite having a specified thickness into a specified cross section configuration by means of a matched die and punch defining said specified cross section configuration, said method comprising:

(a) heating the composite to a temperature of about the melting temperature of the resin prior to said composite entering said matched die and punch;
(b) pulling the heated composite through and in direct contact with said matched die and punch
(c) moving said punch toward and away from said die at a rate to apply rapidly repeating blows to the heated composite to shape the composite into said cross sectional configuration as the heated composite is pulled through the matched die and punch;
and
(d) cooling said composite sufficiently to retain said cross sectional configuration.

2 more elements

Dependencies are inferred from the claim text.

Continuous forming of composites

Life of this patent

Continuous forming of composites

Life of this patent

Abstract

Claims6