US20040217518A1 - Compression molding using a self aligning and activating mold system - Google Patents
Compression molding using a self aligning and activating mold system Download PDFInfo
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- US20040217518A1 US20040217518A1 US10/492,924 US49292404A US2004217518A1 US 20040217518 A1 US20040217518 A1 US 20040217518A1 US 49292404 A US49292404 A US 49292404A US 2004217518 A1 US2004217518 A1 US 2004217518A1
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- mold
- cylinder
- activation
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- mold sections
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
- B21D37/12—Particular guiding equipment, e.g. pliers; Special arrangements for interconnection or cooperation of dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/033—Deforming tubular bodies
- B21D26/039—Means for controlling the clamping or opening of the moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B1/00—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen
- B30B1/32—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by plungers under fluid pressure
- B30B1/34—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by plungers under fluid pressure involving a plurality of plungers acting on the platen
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
- B29C2043/5808—Measuring, controlling or regulating pressure or compressing force
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
- B29C2043/5833—Measuring, controlling or regulating movement of moulds or mould parts, e.g. opening or closing, actuating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
- B29C2043/585—Measuring, controlling or regulating detecting defects, e.g. foreign matter between the moulds, inaccurate position, breakage
- B29C2043/5858—Measuring, controlling or regulating detecting defects, e.g. foreign matter between the moulds, inaccurate position, breakage for preventing tilting of movable mould plate during closing or clamping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
- B29C45/561—Injection-compression moulding
- B29C2045/564—Compression drive means acting independently from the mould closing and clamping means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/20—Opening, closing or clamping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1761—Means for guiding movable mould supports or injection units on the machine base or frame; Machine bases or frames
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49805—Shaping by direct application of fluent pressure
Definitions
- the present invention relates generally to compression molding, and specifically to compression molding using a self-aligning and activating mold system and method.
- Compression molding converts uncured (un-exposed to heat) thermoset sheet molding compounds (SMC) known in the art into various products by applying pressure in a closed mold that is heated to cure (set) the SMC.
- SMC molding typically includes a compression mold mounted into a hydraulic press of sufficient tonnage to generate adequate internal force to cause the heated SMC material to flow and fill the mold.
- a charge (material to be formed) of SMC is placed on a lower section of a mold set. The press is closed under controlled conditions to bring the two mold sections together resulting in compression molding of the SMC.
- These systems typically require a molding pressure of between 750 psi (53 bar) to 1500 psi (103 bar) to adequately flow the compound and fill the mold cavity.
- the molds are typically heated to around 290° F. to 310° F. to complete the cure (set) of the thermoset resin used in the SMC material.
- the mold/press remains closed and under pressure during the cure cycle.
- the duration of the cure cycle is determined by part thickness. A typical cure time for a 0.125 inch thick part would be between 60 and 90 seconds.
- a second conventional molding process is resin transfer molding (RTM).
- RTM injects a liquid thermoset resin into a heated or unheated mold cavity containing a dry glass preform (such as sheets of woven glass material or fiberglass) and allowed to solidify (or cure) into a desired part shape.
- RTM is common and widely used in industry.
- RTM systems typically have upper and lower mold halves. These halves are usually separated using a chain hoist. Once open, the dry glass preform is placed into the mold cavity. The mold halves are then placed back together and the preform is sealed within the mold halves. The resin is injected into the mold cavity, impregnating the preform. The pressure needed to complete the injection is typically 50 psi (3.5 bar). The resin can then cure at either room temperature or a predetermined elevated temperature depending on the desired rate of cure. Once the mixture has solidified, the mold is opened and the part is removed.
- Resin transfer molds typically have a thin nickel tool surface backed by epoxy.
- the structural elements that support the tool surface can include a combination of plywood, fiberglass and steel.
- RTM tools are constructed at relatively low cost when compared to SMC compression molds since little structural integrity is needed to handle its relatively low molding pressures (50 psi compared to 1000 psi in SMC systems). In addition, the RTM process uses no press and has limited infrastructure costs.
- RTM has many limitations that make the process undesirable. These include a frequent inability to make a final shape part; a relatively long cycle time; multi-phase operations are often required; very operator skill dependent; part geometry limitations; limited ability to achieve class A surface finish (i.e. visible or show surface); and part-to-part inconsistency. Given the above limitations, RTM is mainly used for very low production volumes, non-class A surface parts, and simple shapes.
- New SMC compounds have recently been developed that mold at much lower pressures (e.g., between 75 psi to 350 psi). These are now products known in industry as low pressure molding compounds (LPMC) and low pressure sheet molding compounds (LPSMC) which are sold respectively under the trademarks CRYSTIC IMPREG made by Scott Bader Company Ltd of Northamptonshire, England and SMC-LITE made by Ashland Specialty Chemical Company (Composite Polymers Division) of Columbus, Ohio. Such compounds include glass fiber composite impregnated with polyester resins or low viscosity resins including isophthalic and orthosphthalic resins and the like.
- LPMC low pressure molding compounds
- LPSMC low pressure sheet molding compounds
- Such compounds include glass fiber composite impregnated with polyester resins or low viscosity resins including isophthalic and orthosphthalic resins and the like.
- the present invention provides a compression molding apparatus and method using a self-aligning and activating mold (SAAM) system.
- SAAM self-aligning and activating mold
- the present invention uses fabricated steel molds to mold the new low pressure molding compounds (LPMC) and low pressure sheet molding compounds (LPSMC).
- LPMC new low pressure molding compounds
- LPSMC low pressure sheet molding compounds
- an apparatus for compression molding includes a mold set having first and second mold sections and a source of heat for the mold set. At least one activation cylinder is mounted to either the first mold section or the second mold section and has a retraction chamber and an extension chamber. The activation cylinder further includes a cylinder rod having an end mounted to the other of the first and second mold sections.
- a method of compression molding is provided using an apparatus that includes a mold set having first and second mold sections and a source of heat for the mold set. At least one activation cylinder is mounted to one of the first and second mold sections.
- the activation cylinder includes a retraction chamber and an extension chamber, and further includes a first cylinder rod having an end mounted to the other of the first and second mold sections.
- At least one clamping cylinder is mounted to one of the first and second mold sections.
- the clamping cylinder includes a second retraction chamber, a second extension chamber, and a second cylinder rod having a second end releasably mounted to the other of the first and second mold sections.
- the method includes heating the mold set; placing a charge of material to be formed on one of the first and second mold sections; moving one of the mold sections towards the other mold section; actuating the second cylinder rod to meet the one mold section and actuating a lock member to releasably hold the second cylinder rod end to the one mold section; and pressing the mold sections together at a predetermined pressure for a predetermined time to mold the charge of material.
- a method of compression molding is provided using an apparatus including a mold set having a first and second mold section, and a source of heat for the mold set. At least one activation cylinder is connected to one of the mold sections.
- the activation cylinder includes a retraction chamber, an extension chamber, and further includes a cylinder rod having a cylinder rod end mounted to the other of the mold sections.
- the method comprises the steps of heating the mold set; placing a charge of material to be formed on one of the mold sections; moving one mold section towards the other mold section; and pressing the mold sections together at a predetermined pressure for a predetermined time to mold the charge of material.
- FIG. 1 is a perspective view of a compression molding system of the present invention
- FIG. 2 is a side view of a fabricated mold set of the present invention before the mold cavity is machined;
- FIG. 3 is a side view of a fabricated mold set of the present invention machined to a desired work piece shape
- FIG. 4 is a side view of a fabricated mold set of the present invention including reinforcement plates
- FIG. 5 is a side view of the compression molding system of the present invention including a clamping hydraulic cylinder and an activation hydraulic cylinder;
- FIG. 6 is a compression mold system of the present invention in an open position
- FIG. 7 is an alternate embodiment of the present invention using four activation cylinders
- FIG. 8A is a plan view of the alternate embodiment in FIG. 7;
- FIG. 8B is a sectional view cut through line 8 B- 8 B in FIG. 8A;
- FIG. 9 illustrates steps of a compression mold system of the present invention in an open position loading a charge, a closed position molding the charge, and in an open position removing the molded charge;
- FIG. 10 illustrates an alternate embodiment of the present invention having one activation cylinder
- FIGS. 11A & 11B illustrate a top view of FIG. 10 and a sectional view cut through line 11 B- 11 B in FIG. 11A respectively;
- FIG. 12 illustrates an alternate embodiment of the present invention including four activation cylinders and two clamping cylinders.
- FIG. 13 illustrates of the present invention mounted on a truck having activation and clamping cylinders.
- the present invention relates to a compression molding system that combines the advantages of the conventional sheet molding compound (SMC) systems with the resin transfer molding systems (RTM) while eliminating known disadvantages of each of these systems.
- SMC sheet molding compound
- RTM resin transfer molding systems
- the present invention replaces both the large solid steel mold set mounted to a conventional high tonnage hydraulic SMC press and instead uses a fabricated or bar-stock mold set integrated to a series of strategically placed hydraulic cylinders and optional reinforcement plates.
- the present invention is a self-contained, self-aligning and self-activating molding (SAAM) system 20 capable of developing the pressure required for compression molding of new low pressure molding compounds (LPMC) and other similar materials that have low pressure molding and curing capabilities.
- SAAM self-contained, self-aligning and self-activating molding
- LPMC new low pressure molding compounds
- the new LPMC material changes state (such as to a liquid) when heated thereby requiring less pressure to mold a shaped part.
- the present invention achieves the desired molding capabilities in a smaller, lighter and less expensive package compared to conventional SMC molding systems. It is also an improvement over the RTM system in that the limitations of the RTM system as outlined previously, are eliminated.
- the present invention can be operated on a typical six-inch reinforced concrete factory floor, eliminating the need for a larger concrete pad as required by conventional SMC molding systems.
- the working height of the new SAAM molding system 20 can be designed to suit the operators by altering the location of the activation cylinders and defining the desired height of the support pillars.
- the system 20 can be assembled, tested, demonstrated and approved in one facility and shipped assembled to the manufacturing plant as a “turn-key” operation.
- the system provides a cost advantage through reduced capital cost, and a faster time for set up and production.
- FIG. 1 illustrates an embodiment of the present invention utilizing a plurality of mold sets and cylinders connected together. Alternate embodiments of the present invention demonstrate variations in the types of application available by varying the number and configuration of the types of hydraulic cylinders, the mold set shape and the orientation of the molding apparatus.
- the apparatus of the present invention can be oriented horizontally or vertically depending on the particular application.
- FIG. 2 illustrates the mold sections of a mold set before the mold sections have been machined.
- the mold sections can include a plurality of individual plates or a plurality of solid steel bar-stock 16 , connected together in various shapes and sizes to form a mold set the shape and size of a desired part.
- the plates (or bar-stock) 16 can be made of steel or any other material capable of supporting the forces generated during the molding process for a given application.
- the plates (or bar-stock) 16 may be pre-formed to the approximate part shape by methods such as bending, rolling, flame/gas cutting, and forging.
- the plates (or bar-stock) 16 may be connected together along their perimeter using conventional means such as welding, as shown by weld points 26 , or bolting (not shown).
- the plates 16 form a lower mold section 22 and an upper mold section 24 .
- the mold sections 22 and 24 are then machined to create a desired mold cavity 25 corresponding to the part to be molded (FIG. 5).
- Conventional methods such as milling or computer numerically controlled (CNC) machining can be used to machine the mold sections.
- CNC computer numerically controlled
- the mold sections 22 and 24 can also include a heat cavity 43 configured to receive a heating element, which may be, for example, a resistance heater, or, preferably a heated fluid medium such as hot oil or steam (FIG. 2).
- a heating element which may be, for example, a resistance heater, or, preferably a heated fluid medium such as hot oil or steam (FIG. 2).
- a conventional pumping system 86 can be used to heat and pump steam or oil into and out of the heat cavities 43 (FIG. 1).
- the particular heat cavity 43 shown in the figures is representative of the type of cavity required for use of steam as a heating medium. If hot oil is being used, a smaller cavity design will suffice.
- the heating medium is pumped into the heat cavities 43 through heat ports 45 and heats the mold sections 22 and 24 to the required temperature needed to mold a particular work piece (FIGS. 11A & B).
- the molding system 20 can be supported by a plurality of support pillars 14 to place the molding system 20 at a height convenient for a typical worker.
- the support pillars 14 can be affixed on one end to the lower mold section 22 using conventional methods such as bolting or welding.
- the opposite end of the support pillars 14 can be mounted to the floor using conventional methods such as lag bolts.
- the support pillars 14 support the weight of the system 20 and securely fasten the system 20 to the floor to prevent it from moving and reduce excessive vibration during operation.
- FIGS. 1 and 7 show two different types of support pillars 14 , but any number of other possible support pillar configurations could also be used.
- FIG. 3 illustrates the machined mold surfaces 32 and 33 of mold sections 22 and 24 .
- the machined mold surfaces 32 and 33 represent the shape of the part to be molded and define the mold cavity 25 .
- Surfaces 32 and 33 can also be surface finished by conventional means known in the art (e.g., repairing, detailing, grinding, sanding, and polishing) to create an acceptable production surface finish.
- Mating perimeter surfaces 34 and 35 of the upper and lower mold sections serve to define the periphery of mold cavity 25 and are oriented parallel to each other.
- FIG. 4 illustrates the mold sections 22 and 24 including reinforcement plates 36 , activation hydraulic cylinder mounting plate 38 , clamping hydraulic cylinder mounting plate 39 , activation hydraulic cylinder rod end mounting plate 40 , and clamping hydraulic cylinder rod end mounting plate 41 , all of which are mounted to the mold sections 22 and 24 using conventional means such as welding or bolting.
- the illustrated embodiment shown in FIG. 1 is shown with six sets of reinforcement plates 36 (a first set on each upper mold section 24 and a second set on each lower mold section 22 ).
- the reinforcement plates 36 provide strength and stability to the molding system 20 and can vary in quantity, shape, size and location depending on the size and particular embodiment of the molding apparatus.
- Stopping blocks 37 can be mounted to either the perimeter surface 34 of lower mold section 22 or perimeter surface 35 of upper mold section 24 and are used to set the gap between the upper and lower mold sections 22 and 24 by stopping the mold surfaces 32 and 33 from contacting each other.
- the thickness of the part to be molded may be dictated by the size of the stopping blocks 37 .
- the stopping blocks 37 can be various shapes and sizes depending on the particular mold system design and for the particular part to be molded.
- FIG. 5 illustrates an embodiment of the present invention where the mold sections 22 and 24 are connected to an activation hydraulic cylinder 42 and a clamping hydraulic cylinder 44 .
- the activation cylinder 42 can raise and lower the upper mold section 24 to allow convenient removal of a work piece.
- the clamping cylinder 44 allows for additional reinforcement to maintain the mold set in a closed position during operation.
- the activation hydraulic cylinder 42 is mounted to the activation hydraulic cylinder mounting plate 38 on the lower mold section 22 and the clamping hydraulic cylinder 44 is mounted to the clamping hydraulic cylinder mounting plate 39 on the lower mold section 22 .
- the activation hydraulic cylinder 42 has a first cylinder rod 46 attached to a first piston 60 .
- First cylinder rod 46 has a first cylinder rod end 48 that is fixedly mounted to the activation hydraulic cylinder rod end mounting plate 40 on the upper mold section 24 and extends slidably through a closely fitting aperture in plate 38 .
- the activation hydraulic cylinder 42 includes two chambers defined as a first retraction chamber 62 and a first extension chamber 64 . Chambers 62 and 64 can have one or more fluid entry and exit points 80 .
- Fluid is pumped to and from the first retraction and extension chambers 62 and 64 to provide the clamping and extension force needed to move upper mold section 24 to and from lower mold section 22 using a conventional pumping system 86 and computer control system 56 (such as a Position Linear Control (PLC) illustrated in FIG. 1).
- PLC Position Linear Control
- the clamping hydraulic cylinder 44 has a second cylinder rod 50 attached to a second piston 66 .
- the second cylinder rod 50 has a second cylinder rod end 52 that extends into and through the clamping hydraulic cylinder rod end mounting plate 41 and is configured to releasably lock into position into a rod end slide coupler unit 54 .
- the clamping hydraulic cylinder rod end mounting plate 41 includes the rod end slide coupler unit 54 , which is configured to receive the second cylinder rod end 52 .
- FIG. 5 illustrates the rod end slide coupler unit 54 in its closed position locking the second cylinder rod end 52 securely in position.
- the rod end slide coupler unit 54 engages when the upper mold section 24 reaches a predetermined pause position.
- the predetermined pause position is when the upper mold section 24 is within approximately 25-50 mm of the lower mold section 22 .
- the clamping hydraulic cylinder 44 has two chambers defined as a second retraction chamber 68 and a second extension chamber 70 . Each chamber 68 and 70 can have one or more second fluid entry and exit points 82 . Fluid can be pumped to and from the second retraction and second extension chambers 68 and 70 using the pumping system 86 and PLC control system 56 . The clamping hydraulic cylinder 44 assists in providing the clamping and extension forces needed to hold the upper and lower mold sections 22 and 24 together during the molding process.
- the clamping hydraulic cylinder 44 assists the activation hydraulic cylinder 42 in holding the mold sections 22 and 24 in a closed position during operation.
- the activation hydraulic cylinder 42 in combination with the clamping hydraulic cylinder 44 generate the clamping force required to keep mold sections 22 and 24 together and under pressure during the molding and curing stages. Only the activation hydraulic cylinder 42 controls the movement of mold section 24 away from mold section 22 to allow for part removal.
- the clamping hydraulic cylinders 44 differ from activation hydraulic cylinders 42 in four ways.
- the clamping hydraulic cylinders 44 provide clamping force only to hold the mold sections 22 and 24 together during the molding stage.
- the clamping hydraulic cylinders 44 do not aid in raising and lowering the upper mold section 24 .
- the clamping hydraulic cylinders 44 have a unique latching mechanism (the rod end slide coupler unit 54 ).
- the activation hydraulic cylinders 42 have a fixed attachment on the first cylinder rod ends 48 .
- clamping hydraulic cylinders 44 allow unfettered ingress and egress of the charge/part because the second cylinder rod 50 does not reach into the charge/part loading/unloading zone 58 and can be retracted out of the way. Finally, the clamping hydraulic cylinders 44 are more economical, since second cylinder rod 50 has a shorter stroke.
- a system 20 ′ using the present invention includes only four activation hydraulic cylinders 42 and no clamping hydraulic cylinders 44 .
- the activation hydraulic cylinders 42 can open the mold sections 22 ′ and 24 ′ to allow insertion and removal of the molded parts and provide the required pressure for molding of a part.
- the system 20 ′ is inverted in that the activation hydraulic cylinders 42 are attached to a top side of the upper mold section 24 ′.
- the activation cylinder rod end 48 is fixedly attached to the lower mold section 22 ′ instead of the upper mold section 24 ′.
- Reinforcement plates 36 ′ are included in this embodiment and are positioned on the sides and exterior of the mold sections 22 ′ and 24 ′. These optional reinforcement plates 36 ′ add strength and stability of the system in configurations where higher pressures are indicated.
- the system 20 ′′ includes only one activation hydraulic cylinder 42 and no clamping hydraulic cylinders 44 (FIGS. 10-11).
- the cylinder 42 is positioned centrally to distribute the load equally and insure that the perimeter surfaces 34 ′′ and 35 ′′ of upper and lower mold sections 22 ′′ and 24 ′′ remain parallel during operation.
- This embodiment is similarly inverted with the activation cylinder 42 being attached to the topside of the upper mold section 24 ′′.
- This type of single activation system would be used for compression molding of smaller components that require less pressure. The smaller size of the system would also eliminate the need for reinforcement plates 36 used in the previous embodiments.
- FIG. 12 illustrates another embodiment of the molding system 20 ′′′ of the present invention.
- This configuration illustrates four activation cylinders 42 and two clamping cylinders 44 .
- FIG. 13 illustrates a mobile embodiment 20 ′′′′ of the present invention where the molding system is mounted to a truck to provide for the ability to locate the molding process at a desired remote location.
- the molding system is oriented horizontally and is mounted to the truck on tracks to allow the mold sections to slide along the tracks as they move together and apart during operation.
- This embodiment illustrates a compression molding system of the present invention having one activation cylinder 42 and one clamping cylinder 44 .
- the activation hydraulic cylinders 42 and clamping hydraulic cylinders 44 of the present invention are typically arranged on the periphery of the mold tool set except as illustrated in FIGS. 10 and 11. In the illustrated embodiments of FIGS. 1, 7 & 12 , the activation hydraulic cylinders 42 and the clamping hydraulic cylinders 44 are placed symmetrically around the mold set. The activation hydraulic cylinders 42 and clamping hydraulic cylinders 44 can be placed in a wide range of alternative layouts to suit the specific molding conditions and parameters as well as sound engineering requirements.
- the activation hydraulic cylinders 42 and clamping hydraulic cylinders 44 can be placed in an alternating layout or the cylinders 42 and 44 can be in an opposing layout where all the activation cylinders 42 are one side and the clamping cylinders 44 are on the opposite side of the particular system.
- the key to configuring cylinder 42 and 44 placement is to maintain an equal distribution to limit vertical and side mold deflection caused by pressure during production, and keep the upper mold section 24 parallel to the lower mold section 22 .
- each activation hydraulic cylinder 42 can be monitored by linear transducers (not shown), which are encased in the body of each activation hydraulic cylinder 42 .
- the transducers transmit continuous linear position data to the computer control system (PLC) 56 in FIG. 1.
- the PLC 56 interprets incoming data from all the activation hydraulic cylinders 42 in a given system.
- the PLC 56 also monitors and controls hydraulic fluid flow into and out of each activation hydraulic cylinder 42 and clamping hydraulic cylinder 44 via valves at each cylinder's fluid entry and exit points 80 and 82 .
- the PLC 56 can also control the operation of the clamping hydraulic cylinders 44 when they are included in the system.
- the PLC 56 insures uniform speed, position, and self-alignment of the first cylinder rods 46 so that the upper and lower mold sections 22 and 24 always remain parallel and aligned with each other.
- the compression molding process begins with the mold sections 22 and 24 in the open position and heated to approximately 300 degrees Fahrenheit. The heating process is achieved by injecting hot oil or steam through ports 45 and into heat cavities 43 positioned just below the mold surfaces 32 and 33 (FIGS. 8B & 11B). A pre-weighed charge (usually a sheet of material) of a low-pressure molding compound (LPMC) is placed in position on the lower mold section 22 . The PLC 56 commands the molding sequence to initiate. Fluid is pumped out of the first extension chamber 64 and into the first retraction chamber 62 causing the mold sections 22 and 24 to close.
- LPMC low-pressure molding compound
- the closing speed of the cylinders 42 and 44 is slowed to the required forming speed.
- Forming speed is determined by trial and error and differs based on part geometry and LPMC formulation.
- the upper mold section 24 continues to move towards the lower mold section 22 until the mold cavity 25 is closed. This means that either the upper mold section 24 has closed onto the lower mold section 22 with stopping blocks 37 (if used), or the upper mold section 24 has closed against the LPMC material trapped in the mold cavity between the upper and lower mold sections. Once the mold is closed, the “cure time” duration is started.
- the cure time is dependent on the thickness of the part being molded—usually between 60 to 90 seconds per 0.125′′ (3 mm) of thickness. Following the cure cycle completion, a command to open the mold set will be issued by the PLC 56 .
- Fluid is evacuated from retraction chambers 62 and 68 of the activation hydraulic cylinders 42 and clamping hydraulic cylinders 44 while simultaneously being pumped into the extension chambers 64 and 70 .
- the transfer of fluid causes the upper mold section 24 to separate from the lower mold section 22 to a pause position (the same pause position as for the closing phase).
- the rod end slide coupler unit 54 is disengaged, the activation hydraulic cylinder 42 extends, lifting the upper mold section 24 to a position that allows removal of the molded part.
- the clamping cylinder rod 50 can be retracted to increase accessibility if required.
- FIG. 9 illustrates the process showing the mold set in an open/ready position, a closed molding position and a part removal position respectively.
- the steps in the above method would apply excluding the steps related to the clamping hydraulic cylinder 44 .
Abstract
Description
- This application is a continuation-in-part to U.S. non-provisional application Ser. No. 09/982,902 entitled “Hydraulic Pressure Forming Using a Self Aligning and Activating Die System,” filed Oct. 18, 2001. The entire disclosure of U.S. application Ser. No. 09/982,902 is incorporated herein by reference in its entirety.
- 1. Field of the Invention
- The present invention relates generally to compression molding, and specifically to compression molding using a self-aligning and activating mold system and method.
- 2. Discussion of the Prior Art
- Various molding processes exist to produce both simple and complex shapes having a wide range of geometry and thickness. Two existing processes are compression molding and resin transfer molding.
- Compression molding converts uncured (un-exposed to heat) thermoset sheet molding compounds (SMC) known in the art into various products by applying pressure in a closed mold that is heated to cure (set) the SMC. SMC molding typically includes a compression mold mounted into a hydraulic press of sufficient tonnage to generate adequate internal force to cause the heated SMC material to flow and fill the mold. In use, a charge (material to be formed) of SMC is placed on a lower section of a mold set. The press is closed under controlled conditions to bring the two mold sections together resulting in compression molding of the SMC. These systems typically require a molding pressure of between 750 psi (53 bar) to 1500 psi (103 bar) to adequately flow the compound and fill the mold cavity. The molds are typically heated to around 290° F. to 310° F. to complete the cure (set) of the thermoset resin used in the SMC material. The mold/press remains closed and under pressure during the cure cycle. The duration of the cure cycle is determined by part thickness. A typical cure time for a 0.125 inch thick part would be between 60 and 90 seconds.
- Currently, a high tonnage compression press is required to generate the molding pressures necessary to form a standard SMC part. These presses require special installation and deep foundations of reinforced concrete and can weigh many tons and can be over twenty (20) feet in height. Because of their large size and weight, the presses are usually assembled in one facility, disassembled, and then shipped in sections and re-assembled on-site. This increases overall costs and start-up times.
- Thus, conventional SMC presses are expensive and therefore require a long-term investment. Molds (tools) used in a conventional SMC compression process are similarly expensive due to the required structural integrity necessary to handle the high molding pressures. The molds are typically machined from at least two rectangular solid steel billets. These billets are engineered to withstand the high pressures of compression molding. Billet machining can remove as much as fifty percent of the original material, thus adding to the overall cost of the mold design. Because of the size and expense of SMC compression molding operations, SMC part production is usually restricted to high volume parts (e.g., more than 50,000 units annually). Mid and low volume product runs are often prohibitively expensive to produce using this technology.
- A second conventional molding process is resin transfer molding (RTM). RTM injects a liquid thermoset resin into a heated or unheated mold cavity containing a dry glass preform (such as sheets of woven glass material or fiberglass) and allowed to solidify (or cure) into a desired part shape. RTM is common and widely used in industry.
- In use, RTM systems typically have upper and lower mold halves. These halves are usually separated using a chain hoist. Once open, the dry glass preform is placed into the mold cavity. The mold halves are then placed back together and the preform is sealed within the mold halves. The resin is injected into the mold cavity, impregnating the preform. The pressure needed to complete the injection is typically 50 psi (3.5 bar). The resin can then cure at either room temperature or a predetermined elevated temperature depending on the desired rate of cure. Once the mixture has solidified, the mold is opened and the part is removed.
- Resin transfer molds typically have a thin nickel tool surface backed by epoxy. The structural elements that support the tool surface can include a combination of plywood, fiberglass and steel. RTM tools are constructed at relatively low cost when compared to SMC compression molds since little structural integrity is needed to handle its relatively low molding pressures (50 psi compared to 1000 psi in SMC systems). In addition, the RTM process uses no press and has limited infrastructure costs.
- Though relatively inexpensive, RTM has many limitations that make the process undesirable. These include a frequent inability to make a final shape part; a relatively long cycle time; multi-phase operations are often required; very operator skill dependent; part geometry limitations; limited ability to achieve class A surface finish (i.e. visible or show surface); and part-to-part inconsistency. Given the above limitations, RTM is mainly used for very low production volumes, non-class A surface parts, and simple shapes.
- It would be advantageous to overcome the limitations of the RTM systems without the expense and structural requirements of the conventional SMC systems. New SMC compounds have recently been developed that mold at much lower pressures (e.g., between 75 psi to 350 psi). These are now products known in industry as low pressure molding compounds (LPMC) and low pressure sheet molding compounds (LPSMC) which are sold respectively under the trademarks CRYSTIC IMPREG made by Scott Bader Company Ltd of Northamptonshire, England and SMC-LITE made by Ashland Specialty Chemical Company (Composite Polymers Division) of Columbus, Ohio. Such compounds include glass fiber composite impregnated with polyester resins or low viscosity resins including isophthalic and orthosphthalic resins and the like. A new system and method, combining the simplicity and cost effectiveness of an RTM system with the part consistency and class A finish capability of the SMC compression mold process is now possible for molding the new LPMC and LPSMC materials.
- Accordingly, the present invention provides a compression molding apparatus and method using a self-aligning and activating mold (SAAM) system. The present invention uses fabricated steel molds to mold the new low pressure molding compounds (LPMC) and low pressure sheet molding compounds (LPSMC). Using a fabricated mold set integrated to a series of hydraulic cylinders to create a self-contained operating unit, the system eliminates the need for a solid steel tool/mold set operated by a conventional high tonnage hydraulic press.
- In one embodiment of the present invention an apparatus for compression molding includes a mold set having first and second mold sections and a source of heat for the mold set. At least one activation cylinder is mounted to either the first mold section or the second mold section and has a retraction chamber and an extension chamber. The activation cylinder further includes a cylinder rod having an end mounted to the other of the first and second mold sections.
- In another embodiment of the present invention a method of compression molding is provided using an apparatus that includes a mold set having first and second mold sections and a source of heat for the mold set. At least one activation cylinder is mounted to one of the first and second mold sections. The activation cylinder includes a retraction chamber and an extension chamber, and further includes a first cylinder rod having an end mounted to the other of the first and second mold sections. At least one clamping cylinder is mounted to one of the first and second mold sections. The clamping cylinder includes a second retraction chamber, a second extension chamber, and a second cylinder rod having a second end releasably mounted to the other of the first and second mold sections. The method includes heating the mold set; placing a charge of material to be formed on one of the first and second mold sections; moving one of the mold sections towards the other mold section; actuating the second cylinder rod to meet the one mold section and actuating a lock member to releasably hold the second cylinder rod end to the one mold section; and pressing the mold sections together at a predetermined pressure for a predetermined time to mold the charge of material.
- In another embodiment of the present invention a method of compression molding is provided using an apparatus including a mold set having a first and second mold section, and a source of heat for the mold set. At least one activation cylinder is connected to one of the mold sections. The activation cylinder includes a retraction chamber, an extension chamber, and further includes a cylinder rod having a cylinder rod end mounted to the other of the mold sections. The method comprises the steps of heating the mold set; placing a charge of material to be formed on one of the mold sections; moving one mold section towards the other mold section; and pressing the mold sections together at a predetermined pressure for a predetermined time to mold the charge of material.
- While most mold sets of this invention are oriented so as to use upper and lower sections to benefit from the force of gravity in insertion of moldable material in the lower mold section, it will be understood that the invention is equally applicable to configurations wherein the sections are positioned in a side-by-side orientation (See FIG. 13). Thus, it should be understood that the invention contemplates the use of first and second mold sections irrespective of their orientation, and that the use of the terms “upper” and “lower” herein is for illustrative purposes and for ease of understanding, only, and should not be deemed to limit the scope of the invention to any particular orientation of the mold sections.
- Other advantages and features of the present invention will become more apparent to persons having ordinary skill in the art to which the present invention pertains from the following description taken in conjunction with the accompanying figures.
- The foregoing advantages and features, as well as other advantages and features will become apparent with reference to the description and figures below, in which like numerals represent like elements and in which:
- FIG. 1 is a perspective view of a compression molding system of the present invention;
- FIG. 2 is a side view of a fabricated mold set of the present invention before the mold cavity is machined;
- FIG. 3 is a side view of a fabricated mold set of the present invention machined to a desired work piece shape;
- FIG. 4 is a side view of a fabricated mold set of the present invention including reinforcement plates;
- FIG. 5 is a side view of the compression molding system of the present invention including a clamping hydraulic cylinder and an activation hydraulic cylinder;
- FIG. 6 is a compression mold system of the present invention in an open position;
- FIG. 7 is an alternate embodiment of the present invention using four activation cylinders;
- FIG. 8A is a plan view of the alternate embodiment in FIG. 7;
- FIG. 8B is a sectional view cut through
line 8B-8B in FIG. 8A; - FIG. 9 illustrates steps of a compression mold system of the present invention in an open position loading a charge, a closed position molding the charge, and in an open position removing the molded charge;
- FIG. 10 illustrates an alternate embodiment of the present invention having one activation cylinder;
- FIGS. 11A & 11B illustrate a top view of FIG. 10 and a sectional view cut through
line 11B-11B in FIG. 11A respectively; - FIG. 12 illustrates an alternate embodiment of the present invention including four activation cylinders and two clamping cylinders.
- FIG. 13 illustrates of the present invention mounted on a truck having activation and clamping cylinders.
- The present invention relates to a compression molding system that combines the advantages of the conventional sheet molding compound (SMC) systems with the resin transfer molding systems (RTM) while eliminating known disadvantages of each of these systems. The present invention replaces both the large solid steel mold set mounted to a conventional high tonnage hydraulic SMC press and instead uses a fabricated or bar-stock mold set integrated to a series of strategically placed hydraulic cylinders and optional reinforcement plates.
- Generally, the present invention is a self-contained, self-aligning and self-activating molding (SAAM)
system 20 capable of developing the pressure required for compression molding of new low pressure molding compounds (LPMC) and other similar materials that have low pressure molding and curing capabilities. The new LPMC material changes state (such as to a liquid) when heated thereby requiring less pressure to mold a shaped part. The present invention achieves the desired molding capabilities in a smaller, lighter and less expensive package compared to conventional SMC molding systems. It is also an improvement over the RTM system in that the limitations of the RTM system as outlined previously, are eliminated. - The present invention can be operated on a typical six-inch reinforced concrete factory floor, eliminating the need for a larger concrete pad as required by conventional SMC molding systems. The working height of the new
SAAM molding system 20 can be designed to suit the operators by altering the location of the activation cylinders and defining the desired height of the support pillars. Thesystem 20 can be assembled, tested, demonstrated and approved in one facility and shipped assembled to the manufacturing plant as a “turn-key” operation. Thus, the system provides a cost advantage through reduced capital cost, and a faster time for set up and production. - The major components of the
molding system 20 of the present invention are the mold set, hydraulic cylinders, hydraulic power unit, and system controller. FIG. 1 illustrates an embodiment of the present invention utilizing a plurality of mold sets and cylinders connected together. Alternate embodiments of the present invention demonstrate variations in the types of application available by varying the number and configuration of the types of hydraulic cylinders, the mold set shape and the orientation of the molding apparatus. The apparatus of the present invention can be oriented horizontally or vertically depending on the particular application. - FIG. 2 illustrates the mold sections of a mold set before the mold sections have been machined. The mold sections can include a plurality of individual plates or a plurality of solid steel bar-
stock 16, connected together in various shapes and sizes to form a mold set the shape and size of a desired part. The plates (or bar-stock) 16 can be made of steel or any other material capable of supporting the forces generated during the molding process for a given application. The plates (or bar-stock) 16 may be pre-formed to the approximate part shape by methods such as bending, rolling, flame/gas cutting, and forging. The plates (or bar-stock) 16 may be connected together along their perimeter using conventional means such as welding, as shown by weld points 26, or bolting (not shown). Once connected, theplates 16 form alower mold section 22 and anupper mold section 24. Themold sections mold cavity 25 corresponding to the part to be molded (FIG. 5). Conventional methods such as milling or computer numerically controlled (CNC) machining can be used to machine the mold sections. This mold set replaces the need to machine the mold from a single steel billet. - Most mold sets of this invention are oriented to use a lower mold section and an upper mold section to benefit from the force of gravity in insertion of moldable material in the lower mold section. It will be understood that the invention is equally applicable to configurations wherein the mold sections are positioned in a side-by-side orientation (See FIG. 13). Thus, it should be understood that the invention contemplates the use of first and second mold sections irrespective of their orientation, and that the use of the terms “upper” and “lower” herein is for illustrative purposes and for ease of understanding, only, and should not be deemed to limit the scope of the invention to any particular orientation of the mold sections.
- The
mold sections heat cavity 43 configured to receive a heating element, which may be, for example, a resistance heater, or, preferably a heated fluid medium such as hot oil or steam (FIG. 2). Aconventional pumping system 86 can be used to heat and pump steam or oil into and out of the heat cavities 43 (FIG. 1). Theparticular heat cavity 43 shown in the figures is representative of the type of cavity required for use of steam as a heating medium. If hot oil is being used, a smaller cavity design will suffice. The heating medium is pumped into theheat cavities 43 throughheat ports 45 and heats themold sections - The
molding system 20 can be supported by a plurality ofsupport pillars 14 to place themolding system 20 at a height convenient for a typical worker. Thesupport pillars 14 can be affixed on one end to thelower mold section 22 using conventional methods such as bolting or welding. The opposite end of thesupport pillars 14 can be mounted to the floor using conventional methods such as lag bolts. Thesupport pillars 14 support the weight of thesystem 20 and securely fasten thesystem 20 to the floor to prevent it from moving and reduce excessive vibration during operation. FIGS. 1 and 7 show two different types ofsupport pillars 14, but any number of other possible support pillar configurations could also be used. - FIG. 3 illustrates the machined mold surfaces32 and 33 of
mold sections mold cavity 25.Surfaces mold cavity 25 and are oriented parallel to each other. - FIG. 4 illustrates the
mold sections reinforcement plates 36, activation hydrauliccylinder mounting plate 38, clamping hydrauliccylinder mounting plate 39, activation hydraulic cylinder rodend mounting plate 40, and clamping hydraulic cylinder rodend mounting plate 41, all of which are mounted to themold sections upper mold section 24 and a second set on each lower mold section 22). Thereinforcement plates 36 provide strength and stability to themolding system 20 and can vary in quantity, shape, size and location depending on the size and particular embodiment of the molding apparatus. Stopping blocks 37 can be mounted to either theperimeter surface 34 oflower mold section 22 orperimeter surface 35 ofupper mold section 24 and are used to set the gap between the upper andlower mold sections - FIG. 5 illustrates an embodiment of the present invention where the
mold sections hydraulic cylinder 42 and a clampinghydraulic cylinder 44. Theactivation cylinder 42 can raise and lower theupper mold section 24 to allow convenient removal of a work piece. The clampingcylinder 44 allows for additional reinforcement to maintain the mold set in a closed position during operation. - The activation
hydraulic cylinder 42 is mounted to the activation hydrauliccylinder mounting plate 38 on thelower mold section 22 and the clampinghydraulic cylinder 44 is mounted to the clamping hydrauliccylinder mounting plate 39 on thelower mold section 22. The activationhydraulic cylinder 42 has afirst cylinder rod 46 attached to afirst piston 60.First cylinder rod 46 has a firstcylinder rod end 48 that is fixedly mounted to the activation hydraulic cylinder rodend mounting plate 40 on theupper mold section 24 and extends slidably through a closely fitting aperture inplate 38. The activationhydraulic cylinder 42 includes two chambers defined as afirst retraction chamber 62 and afirst extension chamber 64.Chambers extension chambers upper mold section 24 to and fromlower mold section 22 using aconventional pumping system 86 and computer control system 56 (such as a Position Linear Control (PLC) illustrated in FIG. 1). - The clamping
hydraulic cylinder 44 has asecond cylinder rod 50 attached to asecond piston 66. Thesecond cylinder rod 50 has a secondcylinder rod end 52 that extends into and through the clamping hydraulic cylinder rodend mounting plate 41 and is configured to releasably lock into position into a rod endslide coupler unit 54. In the preferred embodiment, the clamping hydraulic cylinder rodend mounting plate 41 includes the rod endslide coupler unit 54, which is configured to receive the secondcylinder rod end 52. FIG. 5 illustrates the rod endslide coupler unit 54 in its closed position locking the secondcylinder rod end 52 securely in position. The rod endslide coupler unit 54 engages when theupper mold section 24 reaches a predetermined pause position. Preferably, the predetermined pause position is when theupper mold section 24 is within approximately 25-50 mm of thelower mold section 22. - The clamping
hydraulic cylinder 44 has two chambers defined as asecond retraction chamber 68 and asecond extension chamber 70. Eachchamber second extension chambers pumping system 86 andPLC control system 56. The clampinghydraulic cylinder 44 assists in providing the clamping and extension forces needed to hold the upper andlower mold sections - FIG. 6 illustrates the embodiment shown in FIG. 5 in an open position with the rod end
slide coupler unit 54 shown in its open position. When themold sections removal zone 58 is created. With the rod endslide coupler unit 54 in its open position, the secondcylinder rod end 52 can be removed from the clamping hydraulic cylinder rodend mounting plate 41, and thefirst cylinder rod 46 can be extended to raise theupper mold section 24. Whenupper mold section 24 is closing towardslower mold section 22, thefirst cylinder rod 46 andsecond cylinder rod 50 provide sufficient forming/closing pressure to mold the part within themold cavity 25. Pressure typically remains constant during the complete curing stage. - In the illustrated embodiment shown in FIGS. 5 & 6, the clamping
hydraulic cylinder 44 assists the activationhydraulic cylinder 42 in holding themold sections hydraulic cylinder 42 in combination with the clampinghydraulic cylinder 44 generate the clamping force required to keepmold sections hydraulic cylinder 42 controls the movement ofmold section 24 away frommold section 22 to allow for part removal. - In summary, the clamping
hydraulic cylinders 44 differ from activationhydraulic cylinders 42 in four ways. First, as stated above, the clampinghydraulic cylinders 44 provide clamping force only to hold themold sections hydraulic cylinders 44 do not aid in raising and lowering theupper mold section 24. Second, the clampinghydraulic cylinders 44 have a unique latching mechanism (the rod end slide coupler unit 54). By comparison, the activationhydraulic cylinders 42 have a fixed attachment on the first cylinder rod ends 48. Third, the clampinghydraulic cylinders 44 allow unfettered ingress and egress of the charge/part because thesecond cylinder rod 50 does not reach into the charge/part loading/unloading zone 58 and can be retracted out of the way. Finally, the clampinghydraulic cylinders 44 are more economical, sincesecond cylinder rod 50 has a shorter stroke. - In an alternate embodiment (FIGS. 7 & 8), a
system 20′ using the present invention includes only four activationhydraulic cylinders 42 and no clampinghydraulic cylinders 44. The activationhydraulic cylinders 42 can open themold sections 22′ and 24′ to allow insertion and removal of the molded parts and provide the required pressure for molding of a part. In this embodiment, thesystem 20′ is inverted in that the activationhydraulic cylinders 42 are attached to a top side of theupper mold section 24′. The activationcylinder rod end 48 is fixedly attached to thelower mold section 22′ instead of theupper mold section 24′. As theupper mold section 24 moves away from thelower mold section 22′ during operation, theactivation cylinders 42 move with theupper mold section 24′.Reinforcement plates 36′ are included in this embodiment and are positioned on the sides and exterior of themold sections 22′ and 24′. Theseoptional reinforcement plates 36′ add strength and stability of the system in configurations where higher pressures are indicated. - In another embodiment, the
system 20″ includes only one activationhydraulic cylinder 42 and no clamping hydraulic cylinders 44 (FIGS. 10-11). In this embodiment, thecylinder 42 is positioned centrally to distribute the load equally and insure that the perimeter surfaces 34″ and 35″ of upper andlower mold sections 22″ and 24″ remain parallel during operation. This embodiment is similarly inverted with theactivation cylinder 42 being attached to the topside of theupper mold section 24″. This type of single activation system would be used for compression molding of smaller components that require less pressure. The smaller size of the system would also eliminate the need forreinforcement plates 36 used in the previous embodiments. - FIG. 12 illustrates another embodiment of the
molding system 20′″ of the present invention. This configuration illustrates fouractivation cylinders 42 and two clampingcylinders 44. FIG. 13 illustrates amobile embodiment 20″″ of the present invention where the molding system is mounted to a truck to provide for the ability to locate the molding process at a desired remote location. In this embodiment the molding system is oriented horizontally and is mounted to the truck on tracks to allow the mold sections to slide along the tracks as they move together and apart during operation. This embodiment illustrates a compression molding system of the present invention having oneactivation cylinder 42 and oneclamping cylinder 44. - The activation
hydraulic cylinders 42 and clampinghydraulic cylinders 44 of the present invention are typically arranged on the periphery of the mold tool set except as illustrated in FIGS. 10 and 11. In the illustrated embodiments of FIGS. 1, 7 & 12, the activationhydraulic cylinders 42 and the clampinghydraulic cylinders 44 are placed symmetrically around the mold set. The activationhydraulic cylinders 42 and clampinghydraulic cylinders 44 can be placed in a wide range of alternative layouts to suit the specific molding conditions and parameters as well as sound engineering requirements. The activationhydraulic cylinders 42 and clampinghydraulic cylinders 44 can be placed in an alternating layout or thecylinders activation cylinders 42 are one side and the clampingcylinders 44 are on the opposite side of the particular system. The key to configuringcylinder upper mold section 24 parallel to thelower mold section 22. - The movement of each activation
hydraulic cylinder 42 can be monitored by linear transducers (not shown), which are encased in the body of each activationhydraulic cylinder 42. The transducers transmit continuous linear position data to the computer control system (PLC) 56 in FIG. 1. ThePLC 56 interprets incoming data from all the activationhydraulic cylinders 42 in a given system. ThePLC 56 also monitors and controls hydraulic fluid flow into and out of each activationhydraulic cylinder 42 and clampinghydraulic cylinder 44 via valves at each cylinder's fluid entry and exit points 80 and 82. ThePLC 56 can also control the operation of the clampinghydraulic cylinders 44 when they are included in the system. ThePLC 56 insures uniform speed, position, and self-alignment of thefirst cylinder rods 46 so that the upper andlower mold sections - The
molding system 20 of the present invention is designed to meet the individual needs of a specific part to be molded. Therefore, the forces acting on themold sections - Hydraulic cylinders must also be evaluated to determine their output force. Output force is a function of the effective area of the cylinders. The cylinder's effective area is calculated using the formula for piston area (cylinder bore) minus the rod diameter area (effective area=piston area−rod diameter). The total output force of the activation
hydraulic cylinders 42 and clampinghydraulic cylinders 44 is specified to exceed the molding force. - The method of using the
molding system 20 of the present invention utilizing an activationhydraulic cylinder 42 in combination with a clampinghydraulic cylinder 44 as shown in FIGS. 1, 5 & 6, will now be described. Alternative methods can be employed depending on the particular embodiment (described above) to be used. The compression molding process begins with themold sections ports 45 and intoheat cavities 43 positioned just below the mold surfaces 32 and 33 (FIGS. 8B & 11B). A pre-weighed charge (usually a sheet of material) of a low-pressure molding compound (LPMC) is placed in position on thelower mold section 22. ThePLC 56 commands the molding sequence to initiate. Fluid is pumped out of thefirst extension chamber 64 and into thefirst retraction chamber 62 causing themold sections - When the
upper mold section 24 reaches the predetermined pause position, (approximately 25 to 50 mm depending on the charge and molding parameters) from thelower mold section 22, the clampinghydraulic cylinder 44, secondcylinder rod end 52 andslide coupler unit 54 are engaged to assist the activationhydraulic cylinder 42 in holding the upper andlower mold sections - At the same time, the closing speed of the
cylinders - The
upper mold section 24 continues to move towards thelower mold section 22 until themold cavity 25 is closed. This means that either theupper mold section 24 has closed onto thelower mold section 22 with stopping blocks 37 (if used), or theupper mold section 24 has closed against the LPMC material trapped in the mold cavity between the upper and lower mold sections. Once the mold is closed, the “cure time” duration is started. - The cure time is dependent on the thickness of the part being molded—usually between 60 to 90 seconds per 0.125″ (3 mm) of thickness. Following the cure cycle completion, a command to open the mold set will be issued by the
PLC 56. - Fluid is evacuated from
retraction chambers hydraulic cylinders 42 and clampinghydraulic cylinders 44 while simultaneously being pumped into theextension chambers upper mold section 24 to separate from thelower mold section 22 to a pause position (the same pause position as for the closing phase). At this position, the rod endslide coupler unit 54 is disengaged, the activationhydraulic cylinder 42 extends, lifting theupper mold section 24 to a position that allows removal of the molded part. Simultaneous with the activationhydraulic cylinder 42 being extended to open themold sections cylinder rod 50 can be retracted to increase accessibility if required. FIG. 9 illustrates the process showing the mold set in an open/ready position, a closed molding position and a part removal position respectively. In an embodiment that does not include a clampinghydraulic cylinder 44, the steps in the above method would apply excluding the steps related to the clampinghydraulic cylinder 44. - The above-described embodiments of the present invention are provided purely for purposes of illustration. Many other variations, modifications, and applications of the invention may be made.
Claims (39)
Priority Applications (2)
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US12/012,096 US20080124418A1 (en) | 2001-10-18 | 2008-01-31 | Compression molding using a self-aligning and activating mold system |
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US09/982,902 US6510720B1 (en) | 2001-10-18 | 2001-10-18 | Hydraulic pressure forming using a self aligning and activating die system |
US10/492,924 US20040217518A1 (en) | 2001-10-18 | 2002-10-11 | Compression molding using a self aligning and activating mold system |
PCT/US2002/032590 WO2003095187A1 (en) | 2001-10-18 | 2002-10-11 | Compression molding using a self-aligning and activating mold system |
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US12/012,096 Abandoned US20080124418A1 (en) | 2001-10-18 | 2008-01-31 | Compression molding using a self-aligning and activating mold system |
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US6889535B1 (en) * | 1999-11-17 | 2005-05-10 | Hyfotec Sweden Ab | Tool assembly |
US6510720B1 (en) * | 2001-10-18 | 2003-01-28 | Hartwick Professionals, Inc. | Hydraulic pressure forming using a self aligning and activating die system |
US6637246B1 (en) * | 2002-10-23 | 2003-10-28 | General Motors Corporation | Tubular part locator for hydroforming apparatus |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11351703B2 (en) * | 2018-05-30 | 2022-06-07 | The Boeing Company | Matched compression die apparatus |
Also Published As
Publication number | Publication date |
---|---|
WO2003033187A1 (en) | 2003-04-24 |
US6510720B1 (en) | 2003-01-28 |
US20080124418A1 (en) | 2008-05-29 |
AU2002367926A1 (en) | 2003-11-11 |
WO2003095187A1 (en) | 2003-11-20 |
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