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.
Claims17
A method for molding a composite body into a composite part comprising the steps of:
- placing a composite body onto an inflexible mold surface;
- placing an elastic mold layer over said composite body to form a molding cavity between said inflexible mold surface and said elastic mold layer, said elastic mold layer having a perimeter;
- placing an elastic pressure layer over said elastic mold layer, said elastic pressure layer having a perimeter;
- placing a flexible expansion control layer over said elastic pressure layer, said flexible expansion control layer having a perimeter and a first portion, second portion and third portion wherein said third portion is located closest to said perimeter, said first portion is located furthest away from said perimeter and said second portion is located between said first portion and said third portion;
- providing a retention frame and a retention rail;
- locating said retention frame over said mold surface such that the perimeters of said mold layer, pressure layer and said first portion of said expansion control layer are located between said mold surface and said retention frame;
- locating said retention rail relative to said retention frame such that said second portion and said third portion of said expansion control layer are located between said retention frame and said retention rail;
- clamping said retention rail to said mold surface in order to seal the perimeters of said mold layer and pressure layer together to form a pressure chamber between said mold layer and pressure layer and to clamp said first and second portions of said expansion control layer and said retention frame to said mold surface;
- clamping said retention rail to said retention frame to provide clamping of said third portion of said expansion control layer between said retention frame and said retention rail;
- pressurizing said pressure chamber for a sufficient time to compact said composite body and form said composite part;
- and
- removing said composite part from said pressure chamber.
Dependencies are inferred from the claim text.