Thermoplastic molding process and apparatus

A system for forming an article from thermoplastic material and fiber, said system comprising:

• means for heating thermoplastic material to form a molten thermoplastic material for blending with the fiber;
• means for blending the molten thermoplastic material with the fibers to form a molten composite material having a concentration of fiber by weight;
• means for extruding the molten composite material to form a flow of composite material gravitating onto a lower portion of a mold for forming the article;
• means for moving the lower portion of the mold in space and time while receiving the flow of composite material to deposit a predetermined quantity of molten composite material thereon conforming to mold cavities of the lower and an upper portion of the mold;
• and
• means for pressing the upper portion of the mold against the predetermined quantity of molten composite material and closing on the lower portion of the mold to form the article.

A system for forming a thermoplastic structural component, said system comprising:

• means for receiving a thermoplastic material;
• means for heating the thermoplastic material;
• means for receiving fibers having a predetermined fiber length;
• means for mixing the heated thermoplastic material with the fibers to form a composite material;
• means for extruding the composite material;
• means for dynamically outputting the extruded composite material at different volumetric flow rates across a plane;
• means for positionally synchronizing a mold to receive the extruded composite material in relation to the different volumetric flow rates across the plane;
• and
• means for pressing the extruded composite material into the mold to form the thermoplastic structural component.

A system for forming a thermoplastic structural component, said system comprising:

• a material receiving unit operable to receive a thermoplastic material and stiffening material;
• a heater unit operable to heat the thermoplastic material;
• an extruder coupled to the material receiving unit and operable to extrude the composite material;
• a dynamic die having a plurality of selectably alterable flow control elements operable to control output of the composite material;
• a mobile unit operable to support a mold and to be dynamically positioned below the dynamic die;
• a controller electrically coupled to said dynamic die and mobile unit, said controller operable to dynamically alter said flow control elements to output the extruded composite material at different volumetric flow rates across a plane and position said mobile unit in synchronicity with the altering of said flow control elements to apply the extruded composite material onto the mold;
• and
• a press operable to receive said mobile unit and press the extruded composite material into the mold.

A system for forming a structural part from thermoplastic material and fiber, said system comprising:

• means for configuring an insert in a mold;
• means for depositing molten extruded composite material on the mold;
• means for forming extruded composite material about at least a portion of the insert;
• means for removing supports, if any, used to configure the insert in the mold;
• means for compressing the extruded composite material to form the structural part;
• and
• means for removing the structural part with the insert at least partially embedded from the mold.