EP3678829A1

EP3678829A1 - Systems and methods for positioning one or more laminates within a mold

Info

Publication number: EP3678829A1
Application number: EP18779039.9A
Authority: EP
Inventors: Recep YALDIZ; Bert RIETMAN
Original assignee: SABIC Global Technologies BV
Current assignee: SHPP Global Technologies BV
Priority date: 2017-09-07
Filing date: 2018-09-07
Publication date: 2020-07-15
Also published as: WO2019049084A1

Abstract

Some systems include first and second mold portions, each defining a molding surface, where the mold portions are movable relative to each other to a closed configuration in which the molding surfaces define at least a portion of a mold cavity, one or more laminate retaining arms, each having a gripper configured to contact a laminate when the laminate is disposed between the mold portions and being movably coupled to one of the mold portions such that a distance between the gripper and the mold portion can be varied. In some systems, to facilitate positioning of a laminate relative to the mold portions: (1) at least one of the arms can be moved independently of at least one other of the arms; and/or (2) a force applied by at least one of the arms to the laminate can be varied.

Description

SYSTEMS AND METHODS FOR POSITIONING ONE OR MORE LAMINATES

WITHIN A MOLD

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority of U.S. Provisional Patent Application No. 62/555,640 filed September 7, 2017, which is hereby incorporated by reference in its entirety.

BACKGROUND

1. Field of Invention

[0002] The present invention relates generally to composite parts, and more specifically, but not by way of limitation, to systems and methods for positioning one or more laminates within a mold to, for example, facilitate overmolding of the laminate(s).

2. Description of Related Art

[0003] Composite parts are often formed by overmolding one or more laminates with an injection molding material. When using a typical overmolding process, the laminate(s) are positioned relative to mold portions of a mold (sometimes referred to as "draping"), the mold portions are closed to define a mold cavity containing the laminate(s), and injection molding material is injected into the mold cavity.

[0004] Such an overmolding process, while usable to produce a composite part that is both strong and light, presents a number of challenges. For one, draping the laminate(s) using traditional processes can result in portion(s) of the laminate(s) being disposed outside of the mold cavity, leading to waste, as well as wrinkling of the laminate(s). Further, when high temperature and pressure injection molding material is injected into the mold, the laminate(s) can be displaced from their desired orientation(s), deformed (e.g., for fiber-reinforced laminate(s), fiber spreading), delaminated, and/or the like. Such issues can result in aesthetic and structural defects in the composite part.

SUMMARY

[0005] The term "coupled" is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are "coupled" may be unitary with each other. The terms "a" and "an" are defined as one or more unless this disclosure explicitly requires otherwise. The term "substantially" is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed embodiment, the term "substantially" may be substituted with "within [a percentage] of what is specified, where the percentage includes .1, 1, 5, and 10 percent.

[0006] The phrase "and/or" means and or or. To illustrate, A, B, and/or C includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, "and/or" operates as an inclusive or.

[0007] The terms "comprise" (and any form of comprise, such as "comprises" and "comprising"), "have" (and any form of have, such as "has" and "having"), "include" (and any form of include, such as "includes" and "including"), and "contain" (and any form of contain, such as "contains" and "containing") are open-ended linking verbs. As a result, an apparatus that "comprises," "has," "includes," or "contains" one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, a method that "comprises," "has," "includes," or "contains" one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.

[0008] Any embodiment of any of the apparatuses, systems, and methods can consist of or consist essentially of - rather than comprise/have/include/contain - any of the described steps, elements, and/or features. Thus, in any of the claims, the term "consisting of or "consisting essentially of can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open- ended linking verb.

[0009] Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described.

[0010] The feature or features of one embodiment may be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments.

[0011] Some details associated with the embodiments are described above, and others are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. [0013] FIG. 1A depicts a first embodiment of the present systems that includes a mold having first and second mold portions, which are shown in an open configuration, and laminate retaining arms configured to position one or more laminates relative to the mold portions, one of which is shown in an extended positon, and others of which are shown in retracted positions.

[0014] FIG. IB depicts the system of FIG. 1A, with the mold portions shown in a closed configuration and each of the laminate retaining arms shown in a retracted position.

[0015] FIG. 2 depicts a laminate retaining arm that is suitable for use with some of the present systems and methods.

[0016] FIG. 3 depicts a second embodiment of the present systems.

[0017] FIGs. 4A and 4B depict laminae that are suitable for use with some of the present systems and methods.

[0018] FIG. 5 depicts embodiments of the present methods for positioning one or more laminates relative to mold portions of a mold, and, in some instances, overmolding the laminate(s) with injection molding material.

[0019] FIG. 6 illustrates some of the methods of FIG. 5.

DETAILED DESCRIPTION

[0020] Referring now to the figures, FIGs. 1A and IB depict a first embodiment 10a of the present systems. System 10a includes a mold 14 within which one or more laminates (e.g., 118, FIG. 4A) and a moldable material can be combined to form a composite part. For example, mold 14 includes at least two mold portions (e.g., 18a and 18b), each defining a molding surface 22, where the mold portions are movable relative to each other between an open configuration (FIG. 1A) and a closed configuration (FIG. IB) in which the molding surfaces cooperate to define a mold cavity 26. To illustrate, the moldable material and the laminate(s) can be combined within mold 14 via overmolding, in which the moldable material is injected into mold cavity 26 while the laminate(s) are disposed within the mold cavity, compression molding, in which the moldable material and the laminate(s) are compressed within the mold cavity via movement of the mold portions to the closed configuration, or the like.

[0021] For each of the mold portions, molding surface 22 may include only surface(s)— or portion(s) thereof— that will define a boundary of a part formed by mold 14. For example, each of the mold portions can include mold mating surface(s) 30, or surface(s) along which the mold portion mates with other(s) of the mold portions when the mold portions are in the closed configuration, which do not (or portion(s) of which do not) define a boundary of a part formed by mold 14 and therefore do not (or portion(s) of which do not) form a part of molding surface 22 of the mold portion.

[0022] Mold 14 can be configured, by selecting the shapes of its molding surfaces 22, to form a part having any suitable shape; the following description of molding surfaces 22 is provided solely by way of illustration. For at least one of the mold portions (e.g., each of mold portions 18a and 18b), molding surface 22 can include a first portion 38a and a second portion 38b, where the second portion can be offset from and/or non-coplanar with the first portion. For example, first portion 38a and second portion 38b can be offset from one another via a third portion 38c of the molding surface that is disposed between the first and second portions. And, the first and second portions can be non-coplanar with one another due to at least a portion of third portion 38c being angularly disposed relative to at least a portion of the first portion and at least a portion of the second portion. The molding surface can include a fourth portion 38d, which, as depicted, can be offset from and/or non-coplanar with first portion 38a similarly to as described above for the first portion and second portion 38b. At least a portion of first portion 38a, second portion 38b, third portion 38c, and/or fourth portion 38d can— but need not— be planar, and planar portion(s) of the first portion, second portion, and/or fourth portion can— but need not— be parallel to one another.

[0023] For at least one of the mold portions, molding surface 22 can be characterized as defining a recess 42 (e.g., mold portion 18a) or a protrusion 46 (e.g., mold portion 18b), where first portion 38a, but not second portion 38b, of the molding surface is disposed within the recess or on the protrusion, or the first portion is disposed at a deeper portion of the recess or at a higher portion of the protrusion than is the second portion. Nevertheless, molds of the present systems can include molding surfaces that each have any suitable shape, including a shape having curved (e.g., concave and/or convex) portion(s) and/or planar portion(s), ones of which can be offset from, non-coplanar with, angularly disposed relative to, and/or parallel to one another, a shape that defines recess(es) and/or protrusion(s), and/or the like.

[0024] Relative movement of the mold portions between the open and closed configurations can be accomplished in any suitable fashion, including via one or more actuators 50 coupled to at least one of the mold portions. Such actuator(s) can be electric, hydraulic, pneumatic, and/or the like. As depicted, mold 14 includes two mold portions; however, other molds can each include any suitable number of mold portions, such as, for example, 2, 3, 4, or more mold portions.

[0025] System 10a includes one or more laminate retaining arms (e.g., 54a, 54b, and 54c), each configured to position a laminate relative to the mold portions. For example, each of the laminate retaining arms includes a gripper 58 for contacting a laminate and is movably coupled to one of (but not necessarily a same one of) the mold portions such that the laminate retaining arm is movable relative to the mold portion between a retracted position (e.g., as shown for laminate retaining arm 54a in FIG. IB) and an extended position (e.g., as shown for laminate retaining arm 54a in FIG. 1 A) in which the gripper is farther from the mold portion than when the laminate retaining arm is in the retracted position. In this way, each of the laminate retaining arms can be moved between its retracted and extended positions such that its gripper 58 positions a laminate relative to the mold portions, which includes shaping the laminate, in which the gripper contacts and displaces a portion of the laminate, and/or clamping the laminate, in which the gripper secures the laminate, whether between the gripper and an opposing one of the mold portions or between the gripper and the gripper of an opposing one of the laminate retaining arms. Such movement, for at least one of the laminate retaining arms, can be performed independently of (e.g., without requiring) movement of the mold portions.

[0026] At least one of the laminate retaining arms can be moved to a position in which its gripper 58 contacts, or comes within 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 millimeter(s) of, an opposing one of the mold portions or the gripper of an opposing one of the laminate retaining arms. In some instances, such a laminate retaining arm can be moved to such a position whether or not the mold portions are in the closed configuration. At least by having this range of movement, such a laminate retaining arm can provide increased flexibility in positioning of a laminate.

[0027] In system 10a, each of the laminate retaining arms is positioned such that its gripper 58 defines— and thereby renders extendable— a portion of molding surface 22 of the mold portion to which the laminate retaining arm is coupled. To illustrate, for molding surface 22 of mold portion 18b: (1) gripper 58 of laminate retaining arm 54a defines at least a portion of first portion 38a; (2) gripper 58 of laminate retaining arm 54b defines at least a portion of second portion 38b; and (3) gripper 58 of laminate retaining arm 54c defines at least a portion of fourth portion 38d. In other systems, one or more of its laminate retaining arm(s) can each include a gripper that is extendable from— but that may not define— a portion of a molding surface of a mold portion to which the laminate retaining arm is coupled.

[0028] At least two of the laminate retaining arms can be positioned to shape and/or clamp respective portions of a laminate that are each disposed between gripper 58 of one the laminate retaining arms and one of offset and/or non-coplanar portions of molding surface 22 of an opposing one of the mold portions. To illustrate: (1) laminate retaining arm 54a is positioned to shape and/or clamp a portion of a laminate disposed between its gripper 58 and first portion 38a of mold portion 18a's molding surface 22; (2) laminate retaining arm 54b is positioned to shape and/or clamp a portion of a laminate disposed between its gripper 58 and second portion 38b of that molding surface; and (3) laminate retaining arm 54c is positioned to shape and/or clamp a portion of a laminate disposed between its gripper 58 and fourth portion 38d of that molding surface. At least through such positioning, the laminate retaining arms can provide for increased control over positioning of a laminate, and particularly those portion(s) of the laminate that overlie and/or underlie offset and/or non-coplanar portions of a molding surface 22, which may be especially susceptible to wrinkling during draping as well as deformation and delamination during overmolding.

[0029] Movement of the laminate retaining arms can be accomplished in any suitable fashion, including via one or more actuators 70, each coupled to at least one of the laminate retaining arms such that operation of the actuator moves those laminate retaining arm(s) between their retracted and extended positions. At least two of the laminate retaining arms can be coupled to different ones of actuator(s) 70 and/or at least two of the laminate retaining arms can be coupled to same one(s) of actuator(s) 70. Such actuator(s) can be electric, hydraulic, pneumatic, and/or the like.

[0030] At least one of the laminate retaining arms can be moved between its retracted and extended positions independently of (e.g., without requiring) movement of at least one other of the laminate retaining arms between its retracted and extended positions. Such functionality can be accomplished by, for example, providing different one(s) of actuator(s) 70 for moving independently movable ones of the laminate retaining arms. Such independently movable laminate retaining arms can enhance positioning of a laminate relative to the mold portions. As one example, one of the laminate retaining arms that effects a greater displacement of a laminate can be moved to displace and/or clamp the laminate before one of the laminate retaining arms that effects a lesser displacement of the laminate is moved to displace and/or clamp the laminate. In at least this way, wrinkling, stretching, and/or the like of the laminate can be mitigated, and portion(s) of the laminate disposed outside of mold cavity 26 when the mold portions are closed can be reduced or eliminated.

[0031] System 10a can include, for at least one of the laminate retaining arms, one or more sensors 78 configured to capture data indicative of a force applied to a laminate by gripper 58. Sensor(s) 78 can include any suitable sensor, such as, for example, a force sensor, pressure sensor, strain gauge, and/or the like coupled to the laminate retaining arm, a sensor configured to capture data indicative of a power, voltage, current, and/or the like provided to at least one of actuator(s) 74 that moves the laminate retaining arm, and/or the like. [0032] System 10a can include a processor 82 configured to use such data to vary a force applied to the laminate by the gripper via control of the actuator(s) that move the laminate retaining arm. To illustrate, a target force to be applied by the gripper can be specified, and, if data captured by the sensor(s) indicates that a force applied by the gripper differs (e.g., by at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10%) from the target force, the processor can control the actuator(s) to reduce the difference between the target and sensor-indicated forces. For example, if the sensor-indicated force is below the target force, the processor can control the actuator(s) to urge the laminate retaining arm toward its extended position, and, if the sensor- indicated force is above the target force, the processor can control the actuator(s) to relax the laminate retaining arm.

[0033] To further illustrate, a maximum force to be applied by the gripper can be specified, and, if data captured by the sensor(s) indicates that a force applied by the gripper exceeds the maximum force, the processor can control the actuator(s) to reduce the sensor-indicated force (e.g., such that the actuator(s) relax the laminate retaining arm). Similarly, a minimum force to be applied by the gripper can be specified, and, if data captured by the sensor(s) indicates that a force applied by the gripper is below the minimum force, the processor can control the actuator(s) to increase the sensor-indicated force (e.g., such that the actuator(s) urge the laminate retaining arm toward its extended position).

[0034] Any number of the laminate retaining arms can be controlled by processor 82 in one or more of the ways described above, and, if more than two of the laminate retaining arms are so controlled, different target, maximum, and/or minimum applied forces may be specified for grippers 58 of those laminate retaining arms. Such processor-based control can facilitate adequate clamping of a laminate while mitigating undesirable damage to the laminate, allow portions of the laminate more susceptible to undesirable displacement during draping and/or overmolding to be clamped more tightly, allow portions of the laminate more susceptible to damage during clamping to be clamped more loosely, and/or the like.

[0035] Referring additionally to FIG. 2, shown is a laminate retaining arm 54d that may be suitable for use in some of the present systems (e.g., as a laminate retaining arm 54a, 54b, and/or 54c). Laminate retaining arm 54d can be movable relative to its respective mold portion 18c via one or more shafts 90, each of which is coupled to gripper 58 and slidably received by the mold portion. As shown, mold portion 14c can define a recess 94 within which gripper 58 is received when laminate retaining arm 54d is in the retracted position, which can mitigate interference of the gripper with moldable material injected into the mold, reduce the appearance of a witness mark caused by the gripper on a part formed by the mold, and/or the like. [0036] Gripper 58 includes a gripping surface 98 that interfaces with a laminate when the laminate is contacted by the gripper. Gripping surface 98 can be configured to distribute force applied to a laminate by gripper 58 across a relatively large portion of the laminate, thereby reducing the risk of undesirable damage (e.g., fiber breakage, fiber spreading, and/or the like) to the laminate. In particular, the surface area of gripping surface 98 can be greater than or substantially equal to any one of, or between any two of: 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, or 10.0 times a cross-sectional area of one of shaft(s) 90. Gripping surface 98 can be longer than it is wide; to illustrate, a length 102 of the gripping surface can be greater than or substantially equal to any one of, or between any two of: 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, or 5.0 times a width 106 of the gripping surface.

[0037] As shown, gripping surface 98 is smooth; however, gripping surfaces of other grippers can be textured and/or can define grooves, protrusions, and/or the like, which can act to resist slippage of a laminate relative to the gripper. While gripping surface 98 is depicted as planar, gripping surfaces of other grippers can be curved (e.g., concave and/or convex). Some grippers can include a gripping surface that defines one or more channels through which moldable material can flow when the gripper is in contact with a laminate, thereby enhancing contact between the moldable material and the laminate.

[0038] FIG. 3 depicts a second embodiment 10b of the present systems. System 10b can be substantially similar to system 10a, with the primary exception being the number and position of laminate retaining arms. In particular, system 10b includes three additional laminate retaining arms— 54e, 54f, and 54g. As shown: (1) laminate retaining arm 54e is positioned such that its gripper 58 opposes gripper 58 of laminate retaining arm 54a; (2) laminate retaining arm 54f is positioned such that its gripper 58 opposes gripper 58 of laminate retaining arm 58b; and (3) laminate retaining arm 54g is positioned such that its gripper 58 opposes gripper 58 of laminate retaining arm 54c. Such opposing laminate retaining arms can provide increased control and flexibility in positioning a laminate. For example, a portion of the laminate can be secured between grippers of opposing laminate retaining arms while it is displaced (e.g., by simultaneously moving one of the laminate retaining arms toward its extended position and the other of the laminate retaining arms toward its retracted position), can be positioned within mold cavity 26 away from the mold portions (e.g., supported by the laminate retaining arms), and/or the like. Of course, other systems can include any suitable number of laminate retaining arms, such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more laminate retaining arm(s), and such laminate retaining arm(s) can be positioned in any suitable fashion. [0039] Provided by way of illustration, FIG. 4A depicts an exploded view of a laminate 1 18 that may be suitable for use with the present systems and methods. Laminate 1 18 includes 5 laminae, 122a-122e; however, other laminates can include any suitable number of lamian(e), such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, or more lamina(e).

[0040] In laminate 118, each of laminae 122a-122e includes fibers 126 dispersed within a matrix material 130. Fibers (e.g., 126) of a lamina (e.g., any of laminae 122a-122e) can include any suitable fibers, such as, for example, glass fibers, carbon fibers, aramid fibers, polyethylene fibers, polyester fibers, polyamide fibers, ceramic fibers, basalt fibers, steel fibers, and/or the like. A matrix material (e.g., 130) of a lamina (e.g., any of laminae 122a-122e) can include any suitable matrix material, such as, for example, a thermoplastic or thermoset matrix material. A suitable thermoplastic matrix material can include, for example, polyethylene terephthalate (PET), polycarbonate (PC), polybutylene terephthalate (PBT), poly(l,4- cyclohexylidene cyclohexane-l,4-dicarboxylate) (PCCD), glycol-modified polycyclohexyl terephthalate (PCTG), poly(phenylene oxide) (PPO), polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polymethyl methacrylate (PMMA), polyethyleneimine or polyetherimide (PEI) or a derivative thereof, a thermoplastic elastomer (TPE), a terephthalic acid (TP A) elastomer, poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene naphthalate (PEN), a polyamide (PA), polystyrene sulfonate (PSS), polyether ether ketone (PEEK), polyether ketone ketone (PEKK), acrylonitrile butyldiene styrene (ABS), polyphenylene sulfide (PPS), a copolymer thereof, or a blend thereof. A suitable thermoset matrix material can include, for example, an unsaturated polyester resin, a polyurethane, bakelite, duroplast, urea-formaldehyde, diallyl-phthalate, epoxy resin, an epoxy vinylester, a polyimide, a cyanate ester of a polycyanurate, dicyclopentadiene, a phenolic, a benzoxazine, a co-polymer thereof, or a blend thereof.

[0041] In each of laminae 122a-122e, fibers 126 are unidirectional, as in, for example, a lamina formed from a unidirectional tape. More particularly, in laminate 118, fibers 126 of laminae 122a, 122b, 122c, 122d, and 122e extend in directions that are angularly disposed relative to a long dimension of the laminate at 0, 45, 90, -45, and 0 degrees, respectively. Other laminates can include lamina(e) having unidirectional fibers that extend in any suitable direction, such as, for example, one that is angularly disposed relative to a long dimension of the laminate at an angle that is greater than or substantially equal to any one of, or between any two of: 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees.

[0042] Some laminates can include lamina(e) having fibers (e.g., 126) arranged in a woven configuration (e.g., as in a lamina having a plane, twill, satin, basket, leno, mock leno, or the like weave). For example, and referring additionally to FIG. 4B, lamina 122f can include a first set of fibers 128a extending in a first direction 132a and a second set of fibers 128b extending in a second direction 132b that is angularly disposed relative to the first direction, where the first set of fibers is woven with the second set of fibers. A smallest angle 134 between first direction 132a and second direction 132b can be greater than or substantially equal to any one of, or between any two of: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees.

[0043] While laminae 122a-122f each include unidirectional or woven fibers 126, some laminates can include non-woven lamina(e), lamina(e) having discontinuous or short fibers, and/or the like. Laminates usable with the present systems and methods can include any suitable lamina(e), including one or more of any lamina described above, and such lamina(e) can be arranged in any suitable lay-up, whether symmetric or asymmetric. Further, some laminates can include can include sheet(s), film(s), core(s) (e.g., porous, non-porous, honeycomb, and/or the like core(s)), and/or the like, which may or may not comprise fibers (e.g., 126) and can comprise any material described above as a matrix material (e.g., 130).

[0044] Referring now to FIG. 5, shown are embodiments of the present methods for positioning one or more laminates relative to mold portions of a mold, and, in some instances, overmolding the laminate(s) with injection molding material. To begin, one or more laminate(s) (e.g., one or more of any laminate described above) can optionally be heated at step 142. Such heating can be performed using any suitable heat source, such as, for example, an infrared heater, an oven, and/or the like. By heating the laminate(s), the pliability of the laminate(s) can be increased, thereby facilitating shaping of the laminate(s) (described below). At step 146, the laminate(s) can be disposed between a molding surface of a first mold portion (e.g., molding surface 22 of mold portion 18a) and a molding surface of a second mold portion (e.g., molding surface 22 of mold portion 18b).

[0045] In some methods, step 142 can be performed during and/or after step 146 (and/or steps 150, 162, and/or 166, described below); in such methods, at least one of the mold portions can include a heat source for heating the laminate(s), such as, for example, an inductive heater, a heating element, and/or the like. Such an inductive heater can include, for example, one or more inductors (e.g., 148, FIG. 6) disposed within or otherwise coupled to at least one of the mold portions such that, when electrical power is supplied to the inductor(s), those mold portion(s)— which are conductive in such an embodiment— are heated via eddy currents induced in the same. The inductor(s) can be flexible to facilitate their positioning within the mold portion(s). In some embodiments, the inductor(s) can be positioned and/or individually controllable to selectively heat certain portion(s) of the mold portion(s) and/or heat different portions of the mold portion(s) to different temperatures. To illustrate, the inductor(s) can be positioned and/or individually controlled to heat portion(s) of a mold portion at which its molding surface (e.g., 22) changes direction (e.g., where the molding surface curves, turns, defines a corner, and/or the like, such as between second portion 38b and third portion 38c, the third portion and first portion 38a, and/or the like) while not heating, or heating to a lesser degree, other portion(s) of the mold portions. In this fashion, the laminate(s) can be heated in a way that facilitates their shaping while avoiding their undesirable deformation.

[0046] At step 150, the laminate(s) can be shaped by moving one or more laminate retaining arms (e.g., one or more of laminate retaining arms 54a, 54b, and 54c), each relative to the mold portion to which it is movably coupled, such that the laminate retaining arm(s) contact and displace portion(s) of the laminate(s) that are disposed between the mold portions. For clarity, movement of a laminate retaining arm such that the laminate retaining arm contacts a laminate does not necessitate that such movement create such contact.

[0047] As one example, and with reference to FIG. 6: (1) a first one of the laminate retaining arm(s) (e.g., 54a) can be moved relative to its mold portion such that a gripper (e.g., 58) of the first laminate retaining arm contacts and displaces a first portion (e.g., 158a) of a laminate, the first portion being disposed between the mold portions; and (2) a second one of the laminate retaining arm(s) (e.g., 54b) can be moved relative to its mold portion such that a gripper (e.g., 58) of the second laminate retaining arm contacts and displaces a second portion (e.g., 158b) of the laminate, the second portion being disposed between the mold portions. Before such shaping, the laminate can be planar, and, after such shaping, the second portion of the laminate can be offset from and non-coplanar with the first portion of the laminate. Of course, in other methods, the laminate(s) can be contacted and displaced by any suitable number of laminate retaining arms and can thereby assume any suitable shape(s).

[0048] In some methods, the first laminate retaining arm can be used to clamp the first portion of the laminate, and the second laminate retaining arm can be used to clamp the second portion of the laminate. For example, as shown in FIG. 6: (1) first portion 158a of laminate 118 is clamped between gripper 58 of laminate retaining arm 54a and first portion 38a of the opposing mold portion's molding surface 22; and second portion 158b of laminate 118 is clamped between gripper 58 of laminate retaining arm 54b and second portion 38b of that molding surface. In some methods, a portion of a laminate can be clamped between grippers of opposing laminate retaining arms (e.g., laminate retaining arms 54a and 54e of system 10b); in such methods, the portion of the laminate can be clamped before it is displaced. In some methods, one portion of a laminate can be clamped before another portion of the laminate is clamped, which can be facilitated by independently movable laminate retaining arms (described above).

[0049] Some methods include, for at least one of the laminate retaining arm(s), capturing, with one or more sensors (e.g., 78), data indicative of a force applied to a laminate by a gripper (e.g., 58) of the laminate retaining arm, and varying a force applied by the gripper to the laminate based, at least in part, on data captured by the sensor(s). As described above, such sensor-based control can be facilitated by a processor (e.g., 82).

[0050] At step 162, the mold portions can be moved relative to each other to a closed configuration in which the molding surfaces cooperate to define at least a portion of a mold cavity (e.g., 26) within which the laminate(s) are at least partially disposed. Step 150 can be performed before, during, or after step 162; for example, the laminate(s) can be clamped prior to the mold portions reaching the closed position. When overmolding the laminate(s), at step 166, injection molding material can be injected into the mold cavity. Such injection molding material can include, for example, any material described above as a matrix material 130.

[0051] Some of the present systems comprise: a mold including first and second mold portions, each defining a molding surface, wherein the mold portions are movable relative to each other between an open configuration and a closed configuration in which the molding surfaces cooperate to define at least a portion of a mold cavity, and one or more laminate retaining arms, each having a gripper that is configured to contact a laminate when the laminate is disposed between the mold portions and being movably coupled to one of the mold portions such that the arm is movable relative to the mold portion between a retracted position and an extended position in which the gripper is farther from the mold portion than when the arm is in the retracted position.

[0052] In some systems, for at least one of the arm(s), the gripper defines a respective portion of the molding surface of the mold portion to which the arm is movably coupled that is extendable, or the gripper is extendable from a respective portion of the molding surface of the mold portion to which the arm is movably coupled. In some systems, the arm(s) include first and second arms, each movably coupled to a same one of the mold portions, and the respective portion of the second arm is offset from and non-coplanar with the respective portion of the first arm. In some systems, the arm(s) include first and second arms, each movably coupled to a same one of the mold portions, and the first arm is movable from the retracted position and toward the extended position without moving the second arm from the retracted position and toward the extended position. [0053] In some systems, at least one of the arm(s) includes a shaft that is coupled to the gripper and slidably received by the mold portion to which the arm is movably coupled. In some systems, for at least one of the arm(s), the mold portion to which the arm is movably coupled defines a recess that is configured to receive the gripper when the arm is in the retracted position.

[0054] Some systems comprise a laminate disposed between the mold portions and including one or more laminae, each having fibers dispersed within a matrix material, wherein, for at least one of the lamina(e), the fibers include unidirectional fibers, or the fibers include a first set of fibers extending in a first direction and a second set of fibers extending in a second direction that is angularly disposed relative to the first direction, wherein the first set of fibers is woven with the second set of fibers.

[0055] Some systems comprise, for at least one of the arm(s), one or more actuators coupled to the arm and configured to move the arm between the retracted and extended positions, one or more sensors configured to capture data indicative of a force applied by the gripper, and a processor configured to control the actuator(s) to vary a force applied by the gripper based, at least in part, on data captured by the sensor(s).

[0056] Some of the present methods comprise: disposing a laminate between a molding surface of a first mold portion and a molding surface of a second mold portion, shaping the laminate at least by moving a first laminate retaining arm relative to one of the mold portions to which the first arm is coupled such that a gripper of the first arm contacts and displaces a first portion of the laminate that is disposed between the mold portions and clamps the first portion of the laminate, and moving a second laminate retaining arm relative to one of the mold portions to which the second arm is coupled such that a gripper of the second arm contacts and displaces a second portion of the laminate that is disposed between the mold portions and clamps the second portion of the laminate, and moving the mold portions relative to each other to a closed configuration in which the molding surfaces cooperate to define at least a portion of a mold cavity within which the laminate is at least partially disposed. Some methods comprise, after the mold portions reach the closed configuration, injecting injection molding material into the mold cavity.

[0057] In some methods, the second portion of the laminate is clamped before or after the first portion of the laminate is clamped. In some methods, the first and second portions of the laminate are each clamped before the mold portions reach the closed configuration. In some methods, the molding surface of one of the mold portions includes a first portion and a second portion that is offset from and non-coplanar with the first portion, the first portion of the laminate is clamped between the gripper of the first arm and the first portion of the molding surface, and the second portion of the laminate is clamped between the gripper of the second arm and the second portion of the molding surface.

[0058] Some methods comprise heating the laminate before disposing the laminate between the mold portions. In some methods, before shaping, the laminate is planar. In some methods, the laminate includes one or more laminae, each having fibers dispersed within a matrix material, and, for at least one of the lamina(e), the fibers include unidirectional fibers, or the fibers include a first set of fibers extending in a first direction and a second set of fibers extending in a second direction that is angularly disposed relative to the first direction, wherein the first set of fibers is woven with the second set of fibers.

[0059] In some methods, for at least one of the arms, the gripper defines a respective portion of the molding surface of the mold portion to which the arm is coupled that is extendable, or the gripper is extendable from a respective portion of the molding surface of the mold portion to which the arm is coupled. In some methods, the respective portion of the second arm is offset from and non-coplanar with the respective portion of the first arm.

[0060] In some methods, at least one of the arms includes a shaft that is coupled to the gripper and slidably received by the mold portion to which the arm is coupled. In some methods, for at least one of the arms, the mold portion to which the arm is coupled defines a recess that is configured to receive the gripper when the arm is in the retracted position.

[0061] Some methods comprise, for at least one of the arms, capturing, with one or more sensors, data indicative of a force applied by the gripper to the laminate, and varying a force applied by the gripper to the laminate based, at least in part, on data captured by the sensor(s).

[0062] The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

[0063] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) "means for" or "step for," respectively.

Claims

A system comprising:

a mold including:

first and second mold portions, each defining a molding surface;

wherein the mold portions are movable relative to each other between an open configuration and a closed configuration in which the molding surfaces cooperate to define at least a portion of a mold cavity; one or more laminate retaining arms, each:

comprising a gripper that is configured to contact a laminate when the laminate is disposed between the mold portions; and

being movably coupled to one of the mold portions such that the arm is movable relative to the mold portion between a retracted position and an extended position in which the gripper is farther from the mold portion than when the arm is in the retracted position; and

for at least one of the arm(s):

one or more actuators coupled to the arm and configured to move the arm between the retracted and extended positions;

one or more sensors configured to capture data indicative of a force applied by the gripper; and

a processor configured to control the actuator(s) to vary a force applied by the gripper based, at least in part, on data captured by the sensor(s).

The system of claim 1, wherein:

the arm(s) include first and second arms, each movably coupled to a same one of the mold portions; and

the first arm is movable from the retracted position and toward the extended position without moving the second arm from the retracted position and toward the extended position.

The system of claim 1 or 2, wherein, for at least one of the arm(s):

the gripper defines a respective portion of the molding surface of the mold portion to which the arm is movably coupled that is extendable; or

the gripper is extendable from a respective portion of the molding surface of the mold portion to which the arm is movably coupled.

The system of claim 3, wherein:

the respective portion of the second arm is offset from and non-coplanar with the respective portion of the first arm.

The system of any of claims 1-4, wherein at least one of the arm(s) includes a shaft that is coupled to the gripper and slidably received by the mold portion to which the arm is movably coupled.

The system of any of claims 1-5, wherein, for at least one of the arm(s), the mold portion to which the arm is movably coupled defines a recess that is configured to receive the gripper when the arm is in the retracted position.

The system of any of claims 1-6, comprising:

a laminate disposed between the mold portions and including one or more laminae, each comprising fibers dispersed within a matrix material;

wherein, for at least one of the lamina(e):

the fibers include unidirectional fibers; or

the fibers include:

a first set of fibers extending in a first direction; and

a second set of fibers extending in a second direction that is angularly disposed relative to the first direction;

wherein the first set of fibers is woven with the second set of fibers.

A method comprising:

disposing a laminate between a molding surface of a first mold portion and a molding surface of a second mold portion;

shaping the laminate at least by:

moving a first laminate retaining arm relative to one of the mold portions to which the first arm is coupled such that a gripper of the first arm: contacts and displaces a first portion of the laminate that is disposed between the mold portions; and

clamps the first portion of the laminate; and moving a second laminate retaining arm relative to one of the mold portions to which the second arm is coupled such that a gripper of the second arm: contacts and displaces a second portion of the laminate that is disposed between the mold portions; and

clamps the second portion of the laminate;

wherein the second portion of the laminate is clamped before or after the first portion of the laminate is clamped; and

moving the mold portions relative to each other to a closed configuration in which the molding surfaces cooperate to define at least a portion of a mold cavity within which the laminate is at least partially disposed.

9. The method of claim 8, wherein, before shaping, the laminate is planar.

10. The method of claim 8 or 9, wherein shaping the laminate is performed such that the second portion of the laminate is offset from and non-coplanar with the first portion of the laminate.

11. The method of any of claims 8-10, wherein:

the molding surface of one of the mold portions includes a first portion and a second portion that is offset from and non-coplanar with the first portion; the first portion of the laminate is clamped between the gripper of the first arm and the first portion of the molding surface; and

the second portion of the laminate is clamped between the gripper of the second arm and the second portion of the molding surface.

12. The method of any of claims 8-11, wherein the first and second portions of the laminate are each clamped before the mold portions reach the closed configuration.

13. The method of any of claims 8-12, comprising heating the laminate before disposing the laminate between the mold portions.

14. The method of any of claims 8-13, comprising, after the mold portions reach the closed configuration, injecting injection molding material into the mold cavity.

15. The method of any of claims 8-14, wherein: the laminate includes one or more laminae, each comprising fibers dispersed within a matrix material; and

for at least one of the lamina(e):

the fibers include unidirectional fibers; or

the fibers include:

a first set of fibers extending in a first direction; and

wherein the first set of fibers is woven with the second set of fibers.

The method of any of claims 8-15, comprising, for at least one of the arms:

capturing, with one or more sensors, data indicative of a force applied by the gripper to the laminate; and

varying a force applied by the gripper to the laminate based, at least in part, on data captured by the sensor(s).

The method of any of claims 8-16, wherein, for at least one of the arms:

the gripper defines a respective portion of the molding surface of the mold portion to which the arm is coupled that is extendable; or

the gripper is extendable from a respective portion of the molding surface of the mold portion to which the arm is coupled.

The method of claim 17, wherein the respective portion of the second arm is offset from and non-coplanar with the respective portion of the first arm.

The method of any of claims 8-18, wherein at least one of the arms includes a shaft that is coupled to the gripper and slidably received by the mold portion to which the arm is coupled.

The method of any of claims 8-19, wherein, for at least one of the arms, the mold portion to which the arm is coupled defines a recess that is configured to receive the gripper when the arm is in the retracted position.