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US 6,143,215 AGranted
Method and apparatus for molding composite articles
AssigneeVEC Technology, Inc.
InventorsRobert P. McCollum, Gene E. Kirila, II
Life of this patent
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Abstract
A method and apparatus for molding composite articles can include a pair of opposed hollow mold sections having first and second molding membranes which define a mold plenum therebetween. Each mold section can be filled with a substantially noncompressible, thermally conductive fluid. The temperature of the mold plenum can be controlled by regulating the temperature of the thermally conductive fluid. Sensing of various parameters during the injection and curing processes of the molding fluid, for example pressure, flowrate, temperature and filling of the plenum can be used to optimize the molding process.
Claims26
A method of molding an article comprising:
- (a) arranging first and second rigid hollow mold sections in a spaced apart opposed relationship;
- (b) defining a mold plenum between a first semi-rigid membrane attached to a side of said first hollow mold section and a second semi-rigid membrane attached to a side of said second hollow mold section adjacent said first semi-rigid membrane such that said first and second semi-rigid membranes are disposed opposite each other forming therebetween said mold plenum whenever said first and second hollow mold sections are closed together to mold articles;
- (c) filling said first and second rigid hollow mold sections with a substantially noncompressible backing fluid such that molding pressure produced in said mold plenum is transmitted from said first and second semi-rigid membranes to said first and second rigid hollow mold sections;
- (d) accommodating thermal expansion of said backing fluid by an expansion chamber in fluid communication with said first and second rigid hollow mold sections;
- (e) injecting molding fluid into said mold plenum to produce a molded part;
- (f) monitoring a flow rate at which said injecting molding fluid is carried out;
- (g) sensing at least one parameter indicative of said mold plenum filling with said molding fluid;
- and
- (h) controlling said flow rate responsive to said at least one parameter.
6 more elements
A method of molding a composite article comprising:
- (a) arranging first and second rigid hollow mold sections in a spaced apart opposed relationship;
- (b) defining a mold plenum between a first semi-rigid membrane attached to a side of the first rigid hollow mold section and a second semi-rigid membrane attached to a side of said second rigid hollow mold section adjacent said first semi-rigid membrane such that said first and second semi-rigid membranes are disposed opposite each other forming therebetween said mold plenum whenever said first and second rigid hollow mold sections are closed together to mold articles;
- (c) filling said first and second rigid hollow mold sections with a substantially noncompressible backing fluid such that molding pressure produced in said mold plenum are transmitted from said first and second semi-rigid membranes to said first and second rigid mold sections;
- (d) accommodating thermal expansion of said backing fluid by an expansion chamber in fluid communication with said first and second rigid mold sections;
- (e) inserting reinforcement materials between said first and second semi-rigid membranes prior to closing said first and second mold sections together to mold articles;
- (f) closing said first and second mold sections towards each other such that said reinforcement materials are sandwiched in said mold plenum;
- (g) rigidly retaining said first and second mold sections together with said reinforcement materials sandwiched in said mold plenum;
- (h) injecting molding fluid under pressure into said mold plenum to produce a composite molded article;
- (i) monitoring a flow rate at which said injecting molding fluid is carried out;
- (j) sensing at least one parameter indicative of said mold plenum filling with said molding fluid;
- and
- (k) controlling said flow rate responsive to said at least one parameter.
9 more elements
A method of molding an article comprising:
- (a) arranging first and second rigid hollow mold sections in a spaced apart opposed relationship;
- (b) defining a mold plenum between a first semi-rigid membrane attached to a side of said first hollow mold section and a second semi-rigid membrane attached to a side of said second hollow mold section adjacent said first semi-rigid membrane such that said first and second semi-rigid membranes are disposed opposite each other forming therebetween said mold plenum whenever said first and second hollow mold sections are closed together to mold articles;
- (c) filling said first and second rigid hollow mold sections with a substantially noncompressible backing fluid such that molding pressure produced in said mold plenum is transmitted from said first and second semi-rigid membranes to said first and second rigid hollow mold sections;
- (d) sensing the temperature of said backing fluid;
- (e) controlling the temperature of said backing fluid to regulate the temperature of said mold plenum by a system of coils disposed within said first and second rigid hollow mold sections;
- (f) injecting molding fluid into said mold plenum to produce a molded part;
- (g) monitoring a flow rate at which said injecting molding fluid is carried out;
- (h) sensing at least one parameter indicative of said mold plenum filling with said molding fluid;
- and
- (i) controlling said flow rate responsive to said at least one parameter.
7 more elements
A method of molding an article comprising:
- (a) arranging first and second rigid hollow mold sections in a spaced apart opposed relationship;
- (b) removably mounting a first semi-rigid membrane attached to a side of the first rigid hollow mold section and a second semi-rigid membrane attached to a side of the second rigid hollow mold section to define a fluid-tight chamber in each mold section;
- (c) disposing the semi-rigid membranes such that the first and second semi-rigid membranes are disposed opposite each other forming therebetween a mold plenum whenever the first and second rigid hollow mold sections are closed together to mold articles;
- (d) filling the fluid tight chamber in the first and second rigid hollow mold sections with a substantially noncompressible backing fluid such that molding pressure produced in the mold plenum is transmitted from the first and second semi-rigid membranes to the first and second rigid hollow mold sections;
- (e) accommodating thermal expansion of the backing fluid by an expansion chamber in fluid communication with the hollow mold sections;
- (f) injecting molding fluid into the mold plenum to produce a molded part;
- (g) monitoring a flow rate at which the injecting of molding fluid is carried out;
- (h) sensing at least one parameter indicative of the mold plenum filling with the molding fluid;
- and
- (i) controlling the flow rate responsive to the at least one parameter.
7 more elements
An injection molding apparatus comprising:
- a. a first rigid hollow mold section having a first semi-rigid membrane connected thereto;
- b. a second rigid hollow mold section having a second semi-rigid membrane connected thereto, said second mold section disposed adjacent said first mold section such that said first and second semi-rigid membranes oppose each other;
- c. said first and second semi-rigid membranes defining a mold plenum therebetween;
- d. a substantially non-compressible backing fluid filling each of said first and second hollow mold sections;
- e. an injection sprue in fluid communication with said mold plenum for delivering molding fluid therein;
- f. at least one flow meter fluidly interposed between a source of said molding fluid and said mold plenum;
- and
- g. at least one sensor operatively associated with at least one of said first mold section, second mold section and said mold plenum, said sensor detecting at least one parameter indicative said mold plenum filling with said molding fluid.
5 more elements
Dependencies are inferred from the claim text.