US20070013105A1 - Post-Forming of Thermoplastic Ducts - Google Patents
Post-Forming of Thermoplastic Ducts Download PDFInfo
- Publication number
- US20070013105A1 US20070013105A1 US11/533,560 US53356006A US2007013105A1 US 20070013105 A1 US20070013105 A1 US 20070013105A1 US 53356006 A US53356006 A US 53356006A US 2007013105 A1 US2007013105 A1 US 2007013105A1
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- US
- United States
- Prior art keywords
- duct
- contour
- thermoplastic
- support structure
- inner support
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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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
- B29C61/00—Shaping by liberation of internal stresses; Making preforms having internal stresses; Apparatus therefor
- B29C61/006—Shaping by liberation of internal stresses; Making preforms having internal stresses; Apparatus therefor the force created by the liberation of the internal stresses being used for compression moulding or for pressing preformed material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B13/00—Conditioning or physical treatment of the material to be shaped
- B29B13/02—Conditioning or physical treatment of the material to be shaped by heating
- B29B13/023—Half-products, e.g. films, plates
- B29B13/024—Hollow bodies, e.g. tubes or profiles
- B29B13/025—Tube ends
-
- 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
- B29C57/00—Shaping of tube ends, e.g. flanging, belling or closing; Apparatus therefor, e.g. collapsible mandrels
-
- 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
- B29C57/00—Shaping of tube ends, e.g. flanging, belling or closing; Apparatus therefor, e.g. collapsible mandrels
- B29C57/02—Belling or enlarging, e.g. combined with forming a groove
- B29C57/04—Belling or enlarging, e.g. combined with forming a groove using mechanical means
- B29C57/06—Belling or enlarging, e.g. combined with forming a groove using mechanical means elastically deformable
-
- 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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
-
- 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
-
- 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
- B29K2277/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as reinforcement
- B29K2277/10—Aromatic polyamides [Polyaramides] or derivatives thereof
-
- 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
- B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
- B29K2309/02—Ceramics
- B29K2309/04—Carbides; Nitrides
-
- 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
- B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
- B29K2309/08—Glass
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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
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
- Y10S425/218—Pipe machine: socket forming apparatus
Definitions
- the present invention relates to apparatuses and methods for forming thermoplastic materials and, more specifically, for post-forming features in thermoplastic ducts.
- Ducts provide transport passageways for a wide variety of applications. For example, tubular ducts are widely used for air flow in aircraft environmental control systems. Similarly, ducts provide passageways for transporting gases for heating and ventilation in other vehicles and in buildings. Water distribution systems, hydraulic systems, and other fluid networks also often use ducts for fluid transport. In addition, solid materials, for example, in particulate form can be delivered through ducts. Ducts for the foregoing and other applications can be formed of metals, plastics, ceramics, composites, and other materials.
- One conventional aircraft environmental control system utilizes a network of ducts to provide air for heating, cooling, ventilation, filtering, humidity control, and/or pressure control of the cabin.
- the ducts are formed of a composite material that includes a thermoset matrix that impregnates, and is reinforced by, a reinforcing material such as Kevlar®, registered trademark of E.I. du Pont de Nemours and Company.
- the thermoset matrix is typically formed of an epoxy or polyester resin, which hardens when it is subjected to heat and pressure.
- Ducts formed of this composite material are generally strong and lightweight, as required in many aircraft applications. However, the manufacturing process can be complicated, lengthy, and expensive, especially for ducts that include contours or features such as beads and bells.
- ducts are formed by forming a disposable plaster mandrel, laying plies of fabric preimpregnated with the thermoset material on the mandrel, and consolidating and curing the plies to form the duct.
- the tools used to mold the plaster mandrel are specially sized and shaped for creating a duct of specific dimensions, so numerous such tools must be produced and maintained for manufacturing different ducts.
- the plaster mandrel is formed and destroyed during the manufacture of one duct, requiring time for curing and resulting in plaster that typically must be removed or destroyed as waste. Additionally, the preimpregnated plies change shape during curing and consolidation and, therefore, typically must be trimmed after curing to achieve the desired dimensions.
- the jigs required for trimming and for locating the proper positions for features such as holes and spuds are also typically used for only a duct of particular dimensions, so numerous jigs are required if different ducts are to be formed. Like the rotatable tools used for forming the mandrels, the jigs require time and expense for manufacture, storage, and maintenance. Additionally, ducts formed of conventional thermoset epoxies typically do not perform well in certain flammability, smoke, and toxicity tests, and the use of such materials can be unacceptable if performance requirements are strict.
- features such as beads typically must be post-formed, or added after the formation of the duct, by disposing a fiberglass rope and/or additional plies on the outer surface of the duct and curing the rope and/or plies. This additional step requires additional manufacture time and labor, adding to the expense of the duct, and the additional materials add to the weight of the duct.
- features can also be formed by providing a corresponding contour on the disposable mandrel, for example, by using a tapered mandrel to form a bell shape in the duct. However, this further complicates the process of preparing the mandrel. Also, the shape or size of the plies can change during curing, resulting in unpredictable changes to the placement of the feature.
- the method should not require the laying of individual plies on a disposable plaster mandrel.
- the method should be compatible with thermoplastic ducts, including reinforced thermoplastic ducts formed from flat sheets, which provide high strength-to-weight ratios and meet strict flammability, smoke, and toxicity standards.
- the method should preferably not require the addition of added materials for forming the features.
- the present invention provides an apparatus and method for thermoplastically forming contours in ducts.
- the ducts can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic laminate, and the contour can be formed by post-forming the duct.
- a thermoplastic material such as flat sheets of reinforced thermoplastic laminate
- the contour can be formed by post-forming the duct.
- individual plies need not be laid on a disposable plaster mandrel, and additional materials do not need to be added to the duct for forming the features.
- the thermoplastic material can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests.
- the method is compatible with ducts that are formed by consolidation joining thermoplastic laminates.
- the present invention provides an apparatus for thermoplastically forming a contour in a thermoplastic duct defining a passage.
- the apparatus includes a longitudinally extending collar with an inner surface that defines a cavity.
- An inner support structure which can be rigid, extends longitudinally in the cavity and has an outer surface that opposes the inner surface of the collar.
- the collar and/or the inner support structure define a mold contour.
- An expansion member which can be formed of an elastomeric material, is disposed between the inner and outer surfaces and partially or continuously around the inner support structure, such that the expansion member can urge a formation portion of the duct against the mold contour and thereby thermoplastically form the duct.
- a heater can be configured to heat the formation portion of the duct to a formation temperature
- an alignment device can be configured to support the duct along a longitudinal axis collinear with that of the collar.
- the expansion member is configured to expand radially and urge the formation portion of the duct radially outward against the mold contour, which is defined by the inner surface of the collar.
- the mold contour can define a bead shape characterized by a continuous slot extending around the outer support.
- the inner support structure can define a channel for receiving the expansion member, and the channel can be adjustable in the longitudinal direction to compress the expansion member and urge the expansion member radially toward the mold contour.
- the inner support structure can include a first portion with a face defining an aperture for receiving a second portion longitudinally, the face and the second portion defining the channel so that insertion of the second portion adjusts the width of the channel.
- An actuator can be provided for adjusting the portion(s) of the inner support structure to expand the expansion member.
- the expansion member can also be an inflatable bladder that is configured to receive a fluid for inflating so that the bladder expands radially outward from the channel and urges the formation portion of the duct toward the mold contour.
- the expansion member is configured to urge the formation portion of the duct radially inward against the mold contour, which is defined by the outer surface of the inner support.
- the inner support can define a tapered bell contour.
- the expansion member can be formed of elastomeric material that expands when heated.
- a plurality of heaters can extend at least partially through the inner support structure, and one or more heaters can be positioned radially outside said cavity and configured to radiate heat radially inward to the duct.
- An insulative material can also be included proximate to the collar to retain heat in the cavity.
- the apparatus includes a rigid inner support structure that is configured to extend longitudinally in the passage of the duct and has an outer surface configured to correspond to a desired configuration of the duct.
- a heater assembly such as a heater positioned within the inner support structure, is configured to heat a formation portion of the duct to at least a formation temperature.
- a heat shrinkable tape is configured to be disposed circumferentially on the formation portion of the duct.
- the outer surface of the inner support structure defines a mold contour and the heat shrinkable material is adapted to contract radially when heated and urge the formation portion of the duct radially inward against the mold contour to thermoplastically form the duct.
- a consolidation joining head can be configured to adjust radially against an interface portion defined by longitudinal edges of the duct. The head urges the interface portion against the inner support, heats the interface portion to at least a glass transition temperature, and thereby consolidation joins the interface portion.
- the present invention also provides a method of thermoplastically forming a contour in a thermoplastic duct.
- the method includes providing a thermoplastic duct between a collar and an inner support structure, for example, a cured thermoplastic duct formed of a reinforced thermoplastic composite material.
- a formation portion of the duct is heated to a formation temperature such as a glass transition temperature, and an expansion member is urged against the duct to thermoplastically form the formation portion of the duct radially against a mold contour defined by the collar and/or the inner support structure.
- Portion(s) of the collar can be separably adjusted to remove the duct therefrom.
- the expansion member can be expanded radially outward or inward against the formation portion of the duct to urge the formation portion against the collar or inner support structure.
- a longitudinal width of a channel can be adjusted to compress the expansion member in the longitudinal direction and expand the expansion member radially outward.
- fluid can be delivered to an inflatable bladder to inflate the bladder and expand the bladder radially outward against the formation portion of the duct.
- the duct can be heated by electrically energizing at least one resistive heater to generate heat and conducting the heat to the formation portion of the duct.
- the heat can also expand the expansion member radially to form the formation portion of the duct. Additionally, after heating the duct, and at least partially concurrent with the urging of the duct, the joint can be cooled to a temperature less than a glass transition temperature.
- a rigid inner support structure is configured to extend longitudinally in a passage of the duct such that a mold contour defined by an outer surface of the inner support structure and corresponding to a desired configuration of the duct is located proximate to a formation portion of the duct.
- Heat shrinkable tape is disposed circumferentially around the formation portion of the duct. The tape and at least a formation portion of the duct are heated to at least a formation temperature, such that the tape contracts radially inward urging the formation portion of the duct radially against the mold contour and thermoplastically forms the duct.
- a consolidation joining head can be adjusted radially inward against an interface portion of the duct defined by longitudinal edges of the duct. The interface portion is thereby urged against the inner support and heated to at least a glass transition temperature, thus, consolidation joining the interface portion.
- FIG. 1 is a perspective view of a forming apparatus according to one embodiment of the present invention.
- FIG. 2 is a perspective view of a thermoplastic duct with a bead formed according to one embodiment of the present invention
- FIG. 3 is a perspective view of a thermoplastic duct with a bell formed according to one embodiment of the present invention
- FIG. 4 is a perspective view of the mold collar and heater of the forming apparatus of FIG. 1 ;
- FIG. 5 is plan view of the first portion of the mold collar of FIG. 4 ;
- FIG. 6 is an exploded perspective view of the holder of the forming apparatus of FIG. 1 ;
- FIG. 7 is an exploded perspective view of the alignment supports of the forming apparatus of FIG. 1 ;
- FIG. 8 is a perspective view of the first portion of the inner support structure of the forming apparatus of FIG. 1 ;
- FIG. 9 is a perspective view of the second portion of the inner support structure of the forming apparatus of FIG. 1 ;
- FIG. 10 is a section view of the forming apparatus of FIG. 1 ;
- FIG. 11 is a section view of the forming apparatus of FIG. 1 with the second portion of the inner support structure inserted into the first portion from its position in FIG. 10 ;
- FIG. 12 is an elevation view of an inner support structure according to one embodiment of the present invention.
- FIG. 13 is a partially cut-away side view of the right side of the inner support structure of FIG. 12 ;
- FIG. 14 is a perspective view of a forming apparatus according to one embodiment of the present invention.
- FIG. 15 is a section view of a forming apparatus according to one embodiment of the present invention.
- FIG. 15A is a perspective view of the duct with an unjoined portion for forming according to one embodiment of the invention.
- FIG. 16 is a perspective view of a forming apparatus according to another embodiment of the present invention.
- FIG. 17 is a perspective view of the inner mandrel of the forming apparatus of FIG. 16 ;
- FIG. 18 is a perspective view of the inner mandrel, duct, and elastomeric layer of the forming apparatus of FIG. 16 ;
- FIG. 19 is an exploded view of the outer mandrel of the forming apparatus of FIG. 16 ;
- FIG. 20 is a perspective view of a forming apparatus according to another embodiment of the present invention.
- FIG. 21 is a perspective view of a forming apparatus according to another embodiment of the present invention.
- the forming apparatus 10 for forming features in a thermoplastic member, such as a duct 12 with a passage 13 , according to one embodiment of the present invention.
- the forming apparatus 10 can be used to form beads 14 and/or bells 15 in ducts 12 as shown in FIGS. 2 and 3 respectively.
- the duct 12 is formed of a composite laminate that includes a thermoplastic matrix and a reinforcing material. Thermoplastic materials are characterized by a transition to a plastic state when heated above a glass transition temperature.
- the duct 12 can be formed of polyetherimide (PEI) or polyphenol sulfide (PPS), both of which can be thermoplastic.
- the duct 12 is formed of a composite material that includes a matrix of thermoplastic PEI that is reinforced with a fabric or fibers that are formed from a reinforcing material such as carbon, glass, or an aramid such as Kevlar®.
- the duct 12 can be formed of other thermoplastic materials, which can be reinforced by other reinforcing materials, or can include no reinforcing materials.
- the duct 12 can be used in numerous applications including, but not limited to, environmental control systems of aerospace vehicles, in which air is delivered through the passage 13 of the duct 12 to provide heating, cooling, ventilation, and/or pressurization of an aircraft cabin.
- the duct 12 can be connected to other ducts or other devices such as ventilators, compressors, filters, and the like.
- the beads 14 and bells 15 can be used to secure the duct 12 to other ducts and devices.
- the bead 14 can correspond to an interior contour of a coupling device such as a clamp that is used to join two ducts 12 .
- the bell 15 can receive an end of another duct 12 , and the two ducts 12 can be held together by friction, glue, fasteners, consolidation joining, or other methods.
- multiple ducts 12 can be connected so that a longitudinal axis of each duct 12 is configured at an angle relative to the longitudinal axis of the adjoining duct(s) 12 .
- the ducts 12 can be connected to form an intricate duct system (not shown) that includes numerous angled or curved ducts 12 for accommodating the devices connected by the duct system and for meeting layout restrictions as required, for example, on an aircraft where space is limited.
- the forming apparatus 10 includes a mold collar 20 , which is shown in FIGS. 4 and 5 .
- the mold collar 20 extends longitudinally from a first end 22 to a second end 24 and defines an inner surface 26 directed toward a cavity 28 .
- the cavity 28 has a circular cross section and corresponds to the outer diameter of the duct 12 , but the cavity 28 can also be non-circular, for example, for forming ducts 12 that have rectangular, triangular, or elliptical cross-section shapes.
- the cavity 28 extends through the collar 20 from the first end 22 to the second end 24 , but in other embodiments the cavity 28 can extend partially therethrough.
- the mold collar 20 can include a single monolithic member or multiple members, such as first and second separable portions 30 , 32 .
- the portions 30 , 32 define holes 36 for receiving bolts (not shown) that connect the portions 30 , 32 , though other fasteners or clamps can similarly be used.
- the mold collar 20 is formed of a thermally conductive material, such as aluminum, steel, titanium, and alloys thereof, and the portions 30 , 32 can be assembled tightly around the duct 12 such that the inner surface 26 of the mold collar 20 contacts the duct 12 and heat can be conducted through the mold collar 20 to the duct 12 during processing.
- the inner surface 26 of the mold collar 20 defines a mold contour 34 , i.e., a contour that corresponds to a desired feature of the duct 12 .
- the mold collar 20 defines a continuous mold contour 34 that extends circumferentially around the inner surface 26 .
- the mold contour 34 of the first portion 30 shown in FIG. 5 is a bead shape that corresponds to the desired bead 14 of FIG. 2 .
- the bead shaped mold contour 34 of FIG. 5 is a continuous slot defined by both portions 30 , 32 of the mold collar 20 that extends around a longitudinal axis of the mold collar 20 .
- the mold contour 34 can comprise multiple non-continuous sections and can extend longitudinally.
- an outer heater 50 can be positioned around the mold collar 20 .
- the outer heater 50 and mold collar 20 are shown assembled without the duct 12 in FIG. 4 .
- the outer heater 50 is configured to be positioned and secured upon the mold collar 20 such that the outer heater 50 is proximate to and aligned with the mold contour 34 .
- the outer heater 50 can be any of a number of different kinds of heaters and can include a single heating device or multiple heating devices, such electrical resistive heaters.
- the outer heater 50 can include two separable segments, as shown in FIG. 4 , that are secured around the mold collar 20 by bolts or another fastening or clamping mechanism.
- the outer heater 50 can be an adjustable clamp heater such as a mica band heater available from Heatron, Inc., Leavenworth, Kans.
- the outer heater 50 can be an integral part of the mold collar 20 .
- An insulative holder 60 defines an aperture 68 , which is used to support the duct 12 with the mold collar 20 and outer heater 50 .
- the holder 60 can be formed of a phenolic material, i.e., a material formed of a thermoset resin, or other heat resistant materials.
- the holder 60 insulates the mold collar 20 to minimize heat loss from the duct 12 during heating.
- the holder 60 can comprise first and second members 62 , 64 that can be separated to facilitate the insertion and removal of the duct 12 , mold collar 20 , and outer heater 50 .
- Bolt holes 66 can receive bolts (not shown) for securing the members 62 , 64 .
- the holder 60 can also define an inner contour 70 within the aperture 68 that corresponds to the duct 12 , mold collar 20 , and/or outer heater 50 .
- the inner contour 70 can define channels, pockets, or other contours that receive at least one of the duct 12 , mold collar 20 , and outer heater 50 .
- the aperture 68 and the inner contour 70 can be configured such that the holder 60 retains the duct 12 , mold collar 20 , and outer heater 50 therein.
- each support 80 comprises a partial hollow cylinder or another shape that correspond to the outside of the duct 12 .
- Each support 80 also includes a rib 82 or other mechanism for engaging or connecting to the holder 60 .
- the ribs 82 correspond with the inner contour 70 of the holder 60 such that the alignment supports 80 can be configured to align the duct 12 , longitudinally in this embodiment, with the mold collar 20 .
- the alignment supports 80 can be connected directly to the mold collar 20 .
- the supports 80 can be formed of a variety of materials including, for example, aluminum, steel, ceramics, polymers, and the like.
- the forming apparatus 10 also includes an inner support structure 90 , which can be formed of various materials such as aluminum, steel, titanium, and alloys thereof. Preferably, at least part of the inner support structure 90 is formed of a thermally conductive material so that heat can be conducted radially outward to the duct 12 as described below.
- the inner support structure 90 includes first and second portions 94 , 96 which are separable, as shown in FIGS. 8 and 9 , respectively.
- the first portion 94 defines an outer surface 92 that corresponds to the inside of the duct 12 .
- a bore 98 extends through the inner support structure 90 in order to provide a material savings and to correspondingly reduce the weight, but the bore can also extend only partially through the support structure 90 or be omitted from the support structure 90 .
- the first portion 94 has a face 100 that defines an aperture 102 for receiving the second portion 96 .
- the second portion 96 also defines a face 104 that, when directed toward face 100 of the first portion 94 , can be received by the first portion 94 .
- a lip 106 limits the extent to which the second portion 96 can be inserted into aperture 102 of the first portion 94 .
- the second portion 96 also includes one or more studs 108 , six shown in FIG.
- An expansion member 130 is disposed on the second portion 96 proximate to the lip 106 .
- the second portion 96 is pulled further into the aperture 102 of the first portion 94 until the expansion member 130 contacts the face 100 of the first portion 94 . Further tightening of the nuts compresses the expansion member 130 in the longitudinal direction between the face 100 and the lip 106 .
- the expansion member 130 is formed of an elastomeric material such as rubber, silicon, neoprene, or latex that is elastically deformable.
- the expansion member 130 can be formed of a moldmaking silicone, such as Shin-Etsu 1300T.
- the inner support structure 90 is positioned in the passage 13 of the duct 12 as shown in FIG. 1 such that the outer surface 92 of the first portion 94 is positioned within and contacts the passage 13 of the duct 12 .
- the inner support structure 90 can include a bore (not shown) to receive an alignment guide 38 , which extends from the first end 22 of the mold collar 20 , so that the inner support structure 90 can be positioned in a predetermined angular position in the duct 12 .
- At least one heater 120 is provided within the passage 13 of the duct 12 to heat the duct 12 during forming. For example, as shown in FIG.
- rod, or cartridge, heaters 120 are disposed in the first portion 94 of the inner support structure 90 and extend from the face 100 into the aperture 102 .
- One such heater 120 is a 500 watt cartridge heater manufactured by Watlow Electric Manufacturing Company, St. Louis, Mo.
- Corresponding holes 122 in the second portion 96 of the inner support structure 90 are structured to receive the rod heaters 120 .
- the rod heaters 120 extend to a position proximate to the expansion member 130 , and the expansion member 130 is positioned at a longitudinal position in the passage 13 of the duct 12 that corresponds to the longitudinal position of the mold contour 34 of the mold collar 20 , for example, as shown in FIGS. 10 and 11 .
- a formation portion 16 of the duct 12 i.e., the portion 16 of the duct 12 that is to be thermoplastically formed to make the bead, is disposed between the expansion member 130 and the mold contour 34 of the mold collar 20 , and the rod heaters 120 are positioned proximate to and generally aligned with the formation portion 16 of the duct 12 .
- the rod heaters 120 can be connected to a power supply 124 , and the outer heater 50 can be connected to the power supply 124 or a different source of power.
- the heaters 50 , 120 are preferably energized such that the formation portion 16 of the duct 12 is heated to a formation temperature, such as a temperature higher than the glass transition temperature of the thermoplastic duct 12 .
- the duct 12 is formed of a composite thermoplastic material comprising PEI reinforced with Kevlar® aramid and has a glass transition temperature of about 417° F.
- the duct can be formed at temperature less than the glass transition temperature, for example, about 350° F., but preferably is formed at higher temperatures to minimize stress on the reinforcing Kevlar® aramid.
- the duct 12 is formed at a temperature of between about 460° F. and 480° F., for a hold or processing time of between about 20 and 45 minutes.
- the expansion member 130 is expanded radially to urge the formation portion 16 of the duct 12 against the mold contour 34 .
- a tightening adjustment of the nuts 109 illustrated by FIG. 11 relative to FIG. 10 , results in the radially outward expansion of the expansion member 130 .
- the tightening of the nuts 109 advances the second portion 96 of the inner support structure 90 into the aperture 102 of the first portion 94 , thereby compressing expansion member 130 longitudinally and expanding the expansion member 130 radially against the duct 12 .
- the expansion member 130 urges the formation portion 16 against the mold contour 34 and thermoplastically forms the formation portion 16 to the desired shape of the duct 12 , which defines a bead in this embodiment.
- the duct 12 can be at least partially cooled in the forming apparatus 10 , for example, to a temperature less than the glass transition temperature.
- an inner support structure 140 comprises a single structure that defines a channel 142 .
- an expansion member which is an elastomeric inflatable bladder 144 defining at least one internal chamber 146 .
- the inflatable bladder 144 is configured to receive a fluid, such as air, into the internal chamber 146 and thereby be expanded radially outwards.
- the inner support structure 140 can be positioned within the passage 13 of the duct 12 , and the duct 12 can be positioned in the mold collar 20 , outer heater 50 , and holder 60 as described above in connection with FIG. 1 .
- a fluid source (not shown) can be fluidly connected to the inflatable bladder 144 , for example, via the fluid line 146 , and heaters 148 , similar to the heaters 120 described above, can be connected to a power supply (not shown), for example, via wires 152 .
- the heaters 148 can be used to heat the duct 12
- the inflatable bladder 144 can be used to urge the formation portion 16 of the duct 12 against the mold contour 34 and thereby thermoplastically form the formation portion 16 to the desired shape of the duct 12 .
- the apparatus 10 can also be used to form other features by changing the configuration of the mold contour 34 .
- the shape of the mold contour 34 can define other continuous shapes extending arcuately around the inner surface 26 of the mold collar 20 , one or more non-continuous shapes, longitudinally extending shapes, and the like.
- the placement of the duct 12 in the forming apparatus 10 determines the position and, in part, the shape of the resulting feature. Therefore, the duct 12 can be inserted into the forming apparatus 10 according to the desired placement of the feature. For example, as shown in FIG.
- the first portion 94 of the inner support structure 90 is wider than the duct 12 , and the duct 12 does not extend through the first portion 94 but rather is inserted to abut the first portion 94 .
- the duct 12 can also be inserted to a lesser extent, i.e., so that the duct 12 does not abut the first portion 94 .
- the first portion 94 of the inner support 90 can fit within the passage 13 of the duct 12 so that the duct 12 can extend, for example, to the first end 22 of the mold collar 20 , or even beyond the mold collar 20 .
- the inner support structure 90 , mold collar 20 , or an additional component of the forming apparatus 10 can function as a placement reference for the duct 12 so that the formation portion 16 of the duct 12 is positioned proximate to the mold contour 34 and the feature is imparted onto the duct 12 at the desired location. Further, the positioning of the duct 12 in the forming apparatus 10 can affect the shape of the feature if the duct 12 is inserted such that the formation portion 16 occurs at the end of the duct 12 and only part of the feature is imparted onto the duct 12 . For example, the mold contour 34 shown in FIG.
- the duct 5 which typically forms the bead 14 on the duct 12 , can also be used to form a short, outwardly flared, or bell shaped, feature by inserting the duct 12 so that the duct 12 extends only partially through the mold contour 34 and the formation portion 16 occurs at the end of the duct 12 .
- a bell feature can also be formed according to the present invention using a forming apparatus 150 such as the one shown in FIG. 14 .
- the forming apparatus 150 includes a base structure 152 that supports a mandrel 160 and a clamping mechanism 170 .
- the mandrel 160 is configured within the clamping mechanism 170 such that the duct 12 can be inserted therebetween.
- the mandrel 160 defines an outer surface 162 that tapers from a first diameter d 1 to a second, smaller diameter d 2 .
- the duct 12 corresponds to the second diameter d 2 and at least a portion of the duct can be configured to correspond to the larger first diameter d 1 .
- FIG. 14 A bell feature can also be formed according to the present invention using a forming apparatus 150 such as the one shown in FIG. 14 .
- the forming apparatus 150 includes a base structure 152 that supports a mandrel 160 and a clamping mechanism 170 .
- the mandrel 160 is configured within the clamping mechanism 1
- the duct 12 can include an interface portion 17 defined by unjoined and overlapping longitudinal edges 18 , 19 of the duct 12 , e.g., a portion of the edges 18 , 19 that were left unjoined in a prior joining process as discussed in U.S. application Ser. No. ______, titled “Consolidation Joining of Thermoplastic Laminate Ducts,” filed concurrently herewith, the entirety of which is incorporated by reference.
- the unjoined edges 18 , 19 allow the duct 12 to be inserted onto the mandrel 160 and configured, at least partially, to the first diameter d 1 .
- the mandrel includes a heater 164 disposed in the wall of the mandrel 160 , though in other embodiments, the heater 164 can instead be positioned within a central bore 166 of the mandrel 160 or otherwise located in the apparatus 150 .
- the clamping mechanism 170 at least partially surrounds the mandrel 160 , and the duct 12 can be inserted axially into the apparatus 150 , e.g., from the right in FIG. 15 , so that the passage 13 of the duct 12 receives the mandrel 160 , and the duct 12 is retained tightly between the clamping mechanism 170 and the mandrel 160 .
- the base structure 152 , the clamping mechanism 170 , and the mandrel 160 can be formed of any material with sufficient strength for supporting the duct 12 during processing, for example, aluminum, steel, titanium, and alloys thereof.
- the inner surface 174 of the clamping mechanism 170 is defined by an elastomeric layer 176 such that the elastomeric layer 176 can be urged radially toward the duct 12 and retained between the clamping mechanism 170 and the mandrel 160 .
- the heater 164 is configured to heat the duct 12 to a formation temperature, e.g., the glass transition temperature, and the elastomeric layer 176 preferably can be expanded to urge the duct 12 against outer surface 174 of the mandrel.
- the elastomeric layer 176 can comprise a heat expandable material that is axially restrained by end plates 178 .
- the heater 164 can be used to heat the formation portion 16 of the duct 12 to a formation temperature and heat the heat expandable elastomeric layer 176 .
- the elastomeric layer 176 expands radially and forces the duct 12 against the mandrel 160 .
- the duct 12 is thermoplastically formed to the shape of the outer surface 162 of the mandrel 160 , for example, the bell 15 .
- the elastomeric layer 176 can instead comprise an inflatable member similar to the inflatable bladder 144 described above.
- the elastomeric layer 176 can also comprise a solid elastomer, and the forming apparatus 150 can include a mechanism for compressing the elastomer, for example, in the axial direction, to thereby expand the elastomer radially inwards. Additionally, the interface portion 17 of the duct 12 can be heated to at least the glass transition temperature and the longitudinal edges 18 , 19 can be consolidation joined by the compressive force exerted thereon by the elastomeric layer 176 as described in U.S. application Ser. No. ______, titled “Consolidation Joining of Thermoplastic Laminate Ducts.”
- an alternative forming apparatus 200 can be used to at least partially encapsulate the duct 12 , heat the duct 12 to a forming temperature, and form the duct 12 against an inner mandrel 204 .
- the inner mandrel 204 has an outer surface 206 that corresponds to the desired shape of the duct 12 .
- the outer surface 206 defines a bell shape, though other mold contours and shapes can similarly be provided including beads, ribs, channels, and the like.
- Bores 208 in the inner mandrel 204 are configured to receive rod or cartridge heaters 210 , which are connected to a power supply 212 , and generate resistive heat.
- the inner mandrel 204 is inserted into the duct 12 as shown in FIG. 18 , and an elastomeric layer 214 is disposed over the duct 12 .
- the elastomeric layer 214 preferably is formed of a heat resistant material that elastically expands when heated, and can be preformed to a hollow cylindrical shape as shown.
- An outer mandrel 216 which can comprise separable sections as shown in FIG. 19 , is then configured to surround the elastomeric layer 214 .
- the outer mandrel 216 is secured in a base support structure 218 , as shown in FIG. 16 , which includes end plates 220 , that are secured by bolts 222 or other fasteners.
- the inner mandrel 204 is formed of a thermally conductive material, such as aluminum, steel, titanium, or alloys thereof, to conduct heat radially outward from the heaters 210 to the duct 12 .
- the outer mandrel 216 and base support structure 218 are preferably sufficiently rigid to support the duct 12 during processing, and the elastomeric layer 214 and/or the outer mandrel 216 can be thermally insulative to reduce heat loss from the forming apparatus 200 .
- the heaters 210 are connected to the power supply 212 and heat the duct to the formation temperature.
- the elastomeric layer 214 expands radially between the outer mandrel 216 and the duct 12 , and preferably provides sufficient expansive force at the formation temperature to urge the duct 12 against the outer surface 206 of the inner mandrel 204 .
- the interface portion 17 of the duct 12 can be heated above the glass transition temperature, and the elastomeric layer 214 can consolidation join the edges 18 , 19 as discussed above in connection with FIG. 15 .
- the duct 12 can be at least partially cooled in the forming apparatus 200 , for example, to a temperature less than the glass transition temperature.
- the clamping mechanism 170 and the outer mandrel 216 of the apparatuses 150 , 200 can comprise a variety of devices that resist the radial force of the elastomeric layers 176 , 214 .
- tape (not shown) can be disposed on the exterior of either of the elastomeric layers 176 , 214 before the elastomeric layer 176 , 214 is heated.
- the tape is sufficiently inelastic so that the tape resists the outwardly radial expansion of the elastomeric layer 176 , 214 forcing the elastomeric layer 176 , 214 to expand radially inward against the duct 12 .
- heat shrinkable tape 230 can be used to configure the duct 12 to the desired configuration.
- a forming apparatus 200 a can be configured by positioning a rigid inner support structure 204 a , similar to the inner mandrel 204 , longitudinally in the passage 13 of the duct 12 so that an outer surface 206 a of the support structure 204 corresponds to the formation portion 16 of the duct 12 .
- the outer support surface 206 a can define a bell section, as shown in FIG. 20 , a bead, or the like.
- the heat shrinkable tape 230 is disposed circumferentially around the formation portion 16 of the duct 12 , and the tape 230 can be disposed in one or more layers on the duct 12 .
- the tape 230 and the duct 12 can be heated by heaters 210 a , which are connected to a power supply 212 a .
- the tape 230 is configured to shrink when heated to the formation temperature of the duct 12 so that the tape 230 contracts in length and urges the formation portion 16 of the duct 12 radially inward against the support structure 204 a .
- the forming apparatus 200 a can include a consolidation joining head 232 , which extends longitudinally and is adapted to be adjusted radially inward against the interface portion 17 of the duct 12 , i.e., in a direction indicated by reference numeral 240 .
- the head 232 is preferably configured to urge the interface portion 17 against the support structure 204 a and heat the interface portion 17 to at least a glass transition temperature of the duct 12 , thereby consolidation joining the edges 18 , 19 at the interface portion 17 , as provided in U.S. application Ser. No. ______, titled “Consolidation Joining of Thermoplastic Laminate Ducts.”
- the head 232 can comprise numerous types of heaters, for example, a flexible heater disposed on an elastomeric block, as discussed in U.S. application Ser. No. ______, titled “Preforming Thermoplastic Ducts,” filed concurrently herewith, the entirety of which is incorporated by reference.”
- FIG. 21 illustrates a forming apparatus 10 a similar to the forming apparatus 10 above.
- the forming apparatus 10 a includes at least one hydraulic actuator 40 for actuating die halves 30 a , 30 b .
- the die halves 30 a , 30 b define a mold contour 34 a , which corresponds to a desired configuration of the duct 12 .
- the die halves 30 a , 30 b also support a plurality of heaters 120 a , which are connected to a power supply 124 a and heat the duct 12 during processing.
- the first actuator 40 is configured to adjust at least one of the die halves 30 a , 30 b to an open position relative to an inner support structure 90 a so that a duct 12 can be inserted into the forming apparatus 10 a and to a closed position so that the duct 12 can be retained between the die halves 30 a , 30 b and the inner support structure 90 a .
- a second actuator (not shown) is configured to adjust a first portion 94 a and/or a second portion (not shown) of the inner support structure 90 a to thereby expand an expansion member 130 a , as described above in connection with FIGS. 10 and 11 .
- actuators can be used to control other functions of the forming apparatuses 10 , 150 , 200 .
- the duct 12 can be formed from a preform (not shown) comprising a flat sheet of thermoplastic laminate, which defines connection features for connecting spuds, brackets, and the like to the duct 12 .
- the preform can define a geometric pattern that corresponds to a desired shape or configuration of the duct 12 , and the geometric pattern can be determined by projecting the desired shape of the duct 12 onto a flat laminate sheet.
- marks can be provided on the preform, for example, to accurately identify the location of post-formed features such as bead and bells or to facilitate the manufacture or assembly of the ducts, as also provided in U.S. application Ser. No. ______, titled “Thermoplastic Laminate Duct.”
- the preform can be bent, or preformed, to the desired shape of the duct and longitudinal ends of the preform can be joined to form the duct.
- Methods and apparatuses for configuring preforms to the bent, or preformed, configuration are provided in U.S. application Ser. No. ______, titled “Preforming Thermoplastic Ducts.”
- Methods and apparatuses for consolidation joining preforms to form ducts are provided in U.S. application Ser. No. ______, titled “Consolidation Joining of Thermoplastic Laminate Ducts.”
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Abstract
An apparatus and method are provided for thermoplastically forming a contour in a thermoplastic duct defining a passage. The apparatus includes a longitudinal collar that defines a cavity and a rigid inner support structure extending longitudinally in the cavity. The collar and/or the inner support structure define a mold contour. One or more heaters are configured to heat at least a formation portion of the duct to a formation temperature. An expansion member, such as an expandable elastomer, which is disposed between an inner surface of the collar and an outer surface of the inner support structure, is configured to urge the formation portion of the duct against the mold contour to thermoplastically form the duct.
Description
- This application is a divisional of U.S. application Ser. No. 10/215,780, filed Aug. 9, 2002, which is hereby incorporated herein in its entirety by reference.
- 1) Field of the Invention
- The present invention relates to apparatuses and methods for forming thermoplastic materials and, more specifically, for post-forming features in thermoplastic ducts.
- 2) Description of Related Art
- Ducts provide transport passageways for a wide variety of applications. For example, tubular ducts are widely used for air flow in aircraft environmental control systems. Similarly, ducts provide passageways for transporting gases for heating and ventilation in other vehicles and in buildings. Water distribution systems, hydraulic systems, and other fluid networks also often use ducts for fluid transport. In addition, solid materials, for example, in particulate form can be delivered through ducts. Ducts for the foregoing and other applications can be formed of metals, plastics, ceramics, composites, and other materials.
- One conventional aircraft environmental control system utilizes a network of ducts to provide air for heating, cooling, ventilation, filtering, humidity control, and/or pressure control of the cabin. In this conventional system, the ducts are formed of a composite material that includes a thermoset matrix that impregnates, and is reinforced by, a reinforcing material such as Kevlar®, registered trademark of E.I. du Pont de Nemours and Company. The thermoset matrix is typically formed of an epoxy or polyester resin, which hardens when it is subjected to heat and pressure. Ducts formed of this composite material are generally strong and lightweight, as required in many aircraft applications. However, the manufacturing process can be complicated, lengthy, and expensive, especially for ducts that include contours or features such as beads and bells. For example, in one conventional manufacturing process, ducts are formed by forming a disposable plaster mandrel, laying plies of fabric preimpregnated with the thermoset material on the mandrel, and consolidating and curing the plies to form the duct. The tools used to mold the plaster mandrel are specially sized and shaped for creating a duct of specific dimensions, so numerous such tools must be produced and maintained for manufacturing different ducts. The plaster mandrel is formed and destroyed during the manufacture of one duct, requiring time for curing and resulting in plaster that typically must be removed or destroyed as waste. Additionally, the preimpregnated plies change shape during curing and consolidation and, therefore, typically must be trimmed after curing to achieve the desired dimensions. The jigs required for trimming and for locating the proper positions for features such as holes and spuds are also typically used for only a duct of particular dimensions, so numerous jigs are required if different ducts are to be formed. Like the rotatable tools used for forming the mandrels, the jigs require time and expense for manufacture, storage, and maintenance. Additionally, ducts formed of conventional thermoset epoxies typically do not perform well in certain flammability, smoke, and toxicity tests, and the use of such materials can be unacceptable if performance requirements are strict.
- Features such as beads typically must be post-formed, or added after the formation of the duct, by disposing a fiberglass rope and/or additional plies on the outer surface of the duct and curing the rope and/or plies. This additional step requires additional manufacture time and labor, adding to the expense of the duct, and the additional materials add to the weight of the duct. As an alternative to post-forming, features can also be formed by providing a corresponding contour on the disposable mandrel, for example, by using a tapered mandrel to form a bell shape in the duct. However, this further complicates the process of preparing the mandrel. Also, the shape or size of the plies can change during curing, resulting in unpredictable changes to the placement of the feature.
- Thus, there exists a need for an improved apparatus and method of forming features such as beads and bells in ducts. The method should not require the laying of individual plies on a disposable plaster mandrel. Preferably, the method should be compatible with thermoplastic ducts, including reinforced thermoplastic ducts formed from flat sheets, which provide high strength-to-weight ratios and meet strict flammability, smoke, and toxicity standards. Further, the method should preferably not require the addition of added materials for forming the features.
- The present invention provides an apparatus and method for thermoplastically forming contours in ducts. The ducts can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic laminate, and the contour can be formed by post-forming the duct. Thus, individual plies need not be laid on a disposable plaster mandrel, and additional materials do not need to be added to the duct for forming the features. Additionally, the thermoplastic material can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. Further, the method is compatible with ducts that are formed by consolidation joining thermoplastic laminates.
- According to one embodiment, the present invention provides an apparatus for thermoplastically forming a contour in a thermoplastic duct defining a passage. The apparatus includes a longitudinally extending collar with an inner surface that defines a cavity. An inner support structure, which can be rigid, extends longitudinally in the cavity and has an outer surface that opposes the inner surface of the collar. The collar and/or the inner support structure define a mold contour. An expansion member, which can be formed of an elastomeric material, is disposed between the inner and outer surfaces and partially or continuously around the inner support structure, such that the expansion member can urge a formation portion of the duct against the mold contour and thereby thermoplastically form the duct. Additionally, a heater can be configured to heat the formation portion of the duct to a formation temperature, and an alignment device can be configured to support the duct along a longitudinal axis collinear with that of the collar.
- According to one aspect of the invention, the expansion member is configured to expand radially and urge the formation portion of the duct radially outward against the mold contour, which is defined by the inner surface of the collar. The mold contour can define a bead shape characterized by a continuous slot extending around the outer support. The inner support structure can define a channel for receiving the expansion member, and the channel can be adjustable in the longitudinal direction to compress the expansion member and urge the expansion member radially toward the mold contour. For example, the inner support structure can include a first portion with a face defining an aperture for receiving a second portion longitudinally, the face and the second portion defining the channel so that insertion of the second portion adjusts the width of the channel. An actuator can be provided for adjusting the portion(s) of the inner support structure to expand the expansion member. The expansion member can also be an inflatable bladder that is configured to receive a fluid for inflating so that the bladder expands radially outward from the channel and urges the formation portion of the duct toward the mold contour. According to another aspect, the expansion member is configured to urge the formation portion of the duct radially inward against the mold contour, which is defined by the outer surface of the inner support. For example, the inner support can define a tapered bell contour.
- The expansion member can be formed of elastomeric material that expands when heated. A plurality of heaters can extend at least partially through the inner support structure, and one or more heaters can be positioned radially outside said cavity and configured to radiate heat radially inward to the duct. An insulative material can also be included proximate to the collar to retain heat in the cavity.
- According to another aspect of the invention, the apparatus includes a rigid inner support structure that is configured to extend longitudinally in the passage of the duct and has an outer surface configured to correspond to a desired configuration of the duct. A heater assembly, such as a heater positioned within the inner support structure, is configured to heat a formation portion of the duct to at least a formation temperature. A heat shrinkable tape is configured to be disposed circumferentially on the formation portion of the duct. The outer surface of the inner support structure defines a mold contour and the heat shrinkable material is adapted to contract radially when heated and urge the formation portion of the duct radially inward against the mold contour to thermoplastically form the duct. Further, a consolidation joining head can be configured to adjust radially against an interface portion defined by longitudinal edges of the duct. The head urges the interface portion against the inner support, heats the interface portion to at least a glass transition temperature, and thereby consolidation joins the interface portion.
- The present invention also provides a method of thermoplastically forming a contour in a thermoplastic duct. According to one embodiment, the method includes providing a thermoplastic duct between a collar and an inner support structure, for example, a cured thermoplastic duct formed of a reinforced thermoplastic composite material. A formation portion of the duct is heated to a formation temperature such as a glass transition temperature, and an expansion member is urged against the duct to thermoplastically form the formation portion of the duct radially against a mold contour defined by the collar and/or the inner support structure. Portion(s) of the collar can be separably adjusted to remove the duct therefrom.
- The expansion member can be expanded radially outward or inward against the formation portion of the duct to urge the formation portion against the collar or inner support structure. According to one aspect of the invention, a longitudinal width of a channel can be adjusted to compress the expansion member in the longitudinal direction and expand the expansion member radially outward. For example, fluid can be delivered to an inflatable bladder to inflate the bladder and expand the bladder radially outward against the formation portion of the duct.
- The duct can be heated by electrically energizing at least one resistive heater to generate heat and conducting the heat to the formation portion of the duct. The heat can also expand the expansion member radially to form the formation portion of the duct. Additionally, after heating the duct, and at least partially concurrent with the urging of the duct, the joint can be cooled to a temperature less than a glass transition temperature.
- According to another aspect of the invention, a rigid inner support structure is configured to extend longitudinally in a passage of the duct such that a mold contour defined by an outer surface of the inner support structure and corresponding to a desired configuration of the duct is located proximate to a formation portion of the duct. Heat shrinkable tape is disposed circumferentially around the formation portion of the duct. The tape and at least a formation portion of the duct are heated to at least a formation temperature, such that the tape contracts radially inward urging the formation portion of the duct radially against the mold contour and thermoplastically forms the duct. Further, a consolidation joining head can be adjusted radially inward against an interface portion of the duct defined by longitudinal edges of the duct. The interface portion is thereby urged against the inner support and heated to at least a glass transition temperature, thus, consolidation joining the interface portion.
- Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
-
FIG. 1 is a perspective view of a forming apparatus according to one embodiment of the present invention; -
FIG. 2 is a perspective view of a thermoplastic duct with a bead formed according to one embodiment of the present invention; -
FIG. 3 is a perspective view of a thermoplastic duct with a bell formed according to one embodiment of the present invention; -
FIG. 4 is a perspective view of the mold collar and heater of the forming apparatus ofFIG. 1 ; -
FIG. 5 is plan view of the first portion of the mold collar ofFIG. 4 ; -
FIG. 6 is an exploded perspective view of the holder of the forming apparatus ofFIG. 1 ; -
FIG. 7 is an exploded perspective view of the alignment supports of the forming apparatus ofFIG. 1 ; -
FIG. 8 is a perspective view of the first portion of the inner support structure of the forming apparatus ofFIG. 1 ; -
FIG. 9 is a perspective view of the second portion of the inner support structure of the forming apparatus ofFIG. 1 ; -
FIG. 10 is a section view of the forming apparatus ofFIG. 1 ; -
FIG. 11 is a section view of the forming apparatus ofFIG. 1 with the second portion of the inner support structure inserted into the first portion from its position inFIG. 10 ; -
FIG. 12 is an elevation view of an inner support structure according to one embodiment of the present invention; -
FIG. 13 is a partially cut-away side view of the right side of the inner support structure ofFIG. 12 ; -
FIG. 14 is a perspective view of a forming apparatus according to one embodiment of the present invention; -
FIG. 15 is a section view of a forming apparatus according to one embodiment of the present invention; -
FIG. 15A is a perspective view of the duct with an unjoined portion for forming according to one embodiment of the invention; -
FIG. 16 is a perspective view of a forming apparatus according to another embodiment of the present invention; -
FIG. 17 is a perspective view of the inner mandrel of the forming apparatus ofFIG. 16 ; -
FIG. 18 is a perspective view of the inner mandrel, duct, and elastomeric layer of the forming apparatus ofFIG. 16 ; -
FIG. 19 is an exploded view of the outer mandrel of the forming apparatus ofFIG. 16 ; -
FIG. 20 is a perspective view of a forming apparatus according to another embodiment of the present invention; and -
FIG. 21 is a perspective view of a forming apparatus according to another embodiment of the present invention. - The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
- Referring now to
FIG. 1 , there is shown a formingapparatus 10 for forming features in a thermoplastic member, such as aduct 12 with apassage 13, according to one embodiment of the present invention. For example, the formingapparatus 10 can be used to formbeads 14 and/orbells 15 inducts 12 as shown inFIGS. 2 and 3 respectively. Preferably, theduct 12 is formed of a composite laminate that includes a thermoplastic matrix and a reinforcing material. Thermoplastic materials are characterized by a transition to a plastic state when heated above a glass transition temperature. For example, theduct 12 can be formed of polyetherimide (PEI) or polyphenol sulfide (PPS), both of which can be thermoplastic. Thermoplastic PEI is available under the trade name Ultem®, a registered trademark of General Electric Company. According to one embodiment of the present invention, theduct 12 is formed of a composite material that includes a matrix of thermoplastic PEI that is reinforced with a fabric or fibers that are formed from a reinforcing material such as carbon, glass, or an aramid such as Kevlar®. Alternatively, theduct 12 can be formed of other thermoplastic materials, which can be reinforced by other reinforcing materials, or can include no reinforcing materials. Theduct 12 can be used in numerous applications including, but not limited to, environmental control systems of aerospace vehicles, in which air is delivered through thepassage 13 of theduct 12 to provide heating, cooling, ventilation, and/or pressurization of an aircraft cabin. Theduct 12 can be connected to other ducts or other devices such as ventilators, compressors, filters, and the like. Thebeads 14 andbells 15 can be used to secure theduct 12 to other ducts and devices. For example, thebead 14 can correspond to an interior contour of a coupling device such as a clamp that is used to join twoducts 12. Similarly, thebell 15 can receive an end of anotherduct 12, and the twoducts 12 can be held together by friction, glue, fasteners, consolidation joining, or other methods. Additionally,multiple ducts 12 can be connected so that a longitudinal axis of eachduct 12 is configured at an angle relative to the longitudinal axis of the adjoining duct(s) 12. Thus, theducts 12 can be connected to form an intricate duct system (not shown) that includes numerous angled orcurved ducts 12 for accommodating the devices connected by the duct system and for meeting layout restrictions as required, for example, on an aircraft where space is limited. - The forming
apparatus 10 includes amold collar 20, which is shown inFIGS. 4 and 5 . Themold collar 20 extends longitudinally from afirst end 22 to asecond end 24 and defines aninner surface 26 directed toward acavity 28. Preferably, thecavity 28 has a circular cross section and corresponds to the outer diameter of theduct 12, but thecavity 28 can also be non-circular, for example, for formingducts 12 that have rectangular, triangular, or elliptical cross-section shapes. In this embodiment, thecavity 28 extends through thecollar 20 from thefirst end 22 to thesecond end 24, but in other embodiments thecavity 28 can extend partially therethrough. Themold collar 20 can include a single monolithic member or multiple members, such as first and secondseparable portions portions holes 36 for receiving bolts (not shown) that connect theportions mold collar 20 is formed of a thermally conductive material, such as aluminum, steel, titanium, and alloys thereof, and theportions duct 12 such that theinner surface 26 of themold collar 20 contacts theduct 12 and heat can be conducted through themold collar 20 to theduct 12 during processing. Theinner surface 26 of themold collar 20 defines amold contour 34, i.e., a contour that corresponds to a desired feature of theduct 12. Preferably, themold collar 20 defines acontinuous mold contour 34 that extends circumferentially around theinner surface 26. For example, themold contour 34 of thefirst portion 30 shown inFIG. 5 is a bead shape that corresponds to the desiredbead 14 ofFIG. 2 . With the first andsecond portions FIG. 4 , the bead shapedmold contour 34 ofFIG. 5 is a continuous slot defined by bothportions mold collar 20 that extends around a longitudinal axis of themold collar 20. Alternatively, themold contour 34 can comprise multiple non-continuous sections and can extend longitudinally. - As shown in
FIG. 4 , anouter heater 50 can be positioned around themold collar 20. For illustrative clarity, theouter heater 50 andmold collar 20 are shown assembled without theduct 12 inFIG. 4 . Preferably, theouter heater 50 is configured to be positioned and secured upon themold collar 20 such that theouter heater 50 is proximate to and aligned with themold contour 34. Theouter heater 50 can be any of a number of different kinds of heaters and can include a single heating device or multiple heating devices, such electrical resistive heaters. Theouter heater 50 can include two separable segments, as shown inFIG. 4 , that are secured around themold collar 20 by bolts or another fastening or clamping mechanism. For example, theouter heater 50 can be an adjustable clamp heater such as a mica band heater available from Heatron, Inc., Leavenworth, Kans. Alternatively, theouter heater 50 can be an integral part of themold collar 20. - An
insulative holder 60, shown inFIG. 6 , defines anaperture 68, which is used to support theduct 12 with themold collar 20 andouter heater 50. Theholder 60 can be formed of a phenolic material, i.e., a material formed of a thermoset resin, or other heat resistant materials. Preferably, theholder 60 insulates themold collar 20 to minimize heat loss from theduct 12 during heating. As illustrated inFIG. 6 , theholder 60 can comprise first andsecond members duct 12,mold collar 20, andouter heater 50. Bolt holes 66 can receive bolts (not shown) for securing themembers holder 60 can also define aninner contour 70 within theaperture 68 that corresponds to theduct 12,mold collar 20, and/orouter heater 50. For example, theinner contour 70 can define channels, pockets, or other contours that receive at least one of theduct 12,mold collar 20, andouter heater 50. Thus, theaperture 68 and theinner contour 70 can be configured such that theholder 60 retains theduct 12,mold collar 20, andouter heater 50 therein. - Similarly, the
holder 60 can be configured to retain one or more longitudinal alignment supports 80, shown individually inFIG. 7 . Eachsupport 80 comprises a partial hollow cylinder or another shape that correspond to the outside of theduct 12. Eachsupport 80 also includes arib 82 or other mechanism for engaging or connecting to theholder 60. Theribs 82 correspond with theinner contour 70 of theholder 60 such that the alignment supports 80 can be configured to align theduct 12, longitudinally in this embodiment, with themold collar 20. Alternatively, the alignment supports 80 can be connected directly to themold collar 20. The supports 80 can be formed of a variety of materials including, for example, aluminum, steel, ceramics, polymers, and the like. - The forming
apparatus 10 also includes aninner support structure 90, which can be formed of various materials such as aluminum, steel, titanium, and alloys thereof. Preferably, at least part of theinner support structure 90 is formed of a thermally conductive material so that heat can be conducted radially outward to theduct 12 as described below. In one embodiment, theinner support structure 90 includes first andsecond portions FIGS. 8 and 9 , respectively. Thefirst portion 94 defines anouter surface 92 that corresponds to the inside of theduct 12. A bore 98 extends through theinner support structure 90 in order to provide a material savings and to correspondingly reduce the weight, but the bore can also extend only partially through thesupport structure 90 or be omitted from thesupport structure 90. Thefirst portion 94 has aface 100 that defines anaperture 102 for receiving thesecond portion 96. Thesecond portion 96 also defines aface 104 that, when directed towardface 100 of thefirst portion 94, can be received by thefirst portion 94. Alip 106 limits the extent to which thesecond portion 96 can be inserted intoaperture 102 of thefirst portion 94. Thesecond portion 96 also includes one ormore studs 108, six shown inFIG. 9 , which extend throughcorresponding holes 110 of thefirst portion 94 when thesecond portion 96 is inserted into thefirst portion 94. Nuts (not shown) can be threaded onto thestuds 108 such that the nuts retain thestuds 108 in theholes 110 and retain thesecond portion 96 in theaperture 102 of thefirst portion 94. Thestuds 108 also serve to align the first andsecond portions - An
expansion member 130 is disposed on thesecond portion 96 proximate to thelip 106. When the nuts are tightened on thestuds 108, as illustrated byFIGS. 10 and 11 , thesecond portion 96 is pulled further into theaperture 102 of thefirst portion 94 until theexpansion member 130 contacts theface 100 of thefirst portion 94. Further tightening of the nuts compresses theexpansion member 130 in the longitudinal direction between theface 100 and thelip 106. Preferably, theexpansion member 130 is formed of an elastomeric material such as rubber, silicon, neoprene, or latex that is elastically deformable. For example, theexpansion member 130 can be formed of a moldmaking silicone, such as Shin-Etsu 1300T. Thus, by tightening the nuts, theexpansion member 130 can be expanded radially outward from thesecond member 96 to urge theduct 12 against themold collar 20. - According to one method of operation, the
inner support structure 90 is positioned in thepassage 13 of theduct 12 as shown inFIG. 1 such that theouter surface 92 of thefirst portion 94 is positioned within and contacts thepassage 13 of theduct 12. Theinner support structure 90 can include a bore (not shown) to receive analignment guide 38, which extends from thefirst end 22 of themold collar 20, so that theinner support structure 90 can be positioned in a predetermined angular position in theduct 12. At least oneheater 120 is provided within thepassage 13 of theduct 12 to heat theduct 12 during forming. For example, as shown inFIG. 10 , rod, or cartridge,heaters 120 are disposed in thefirst portion 94 of theinner support structure 90 and extend from theface 100 into theaperture 102. Onesuch heater 120 is a 500 watt cartridge heater manufactured by Watlow Electric Manufacturing Company, St. Louis, Mo. Correspondingholes 122 in thesecond portion 96 of theinner support structure 90 are structured to receive therod heaters 120. Preferably, therod heaters 120 extend to a position proximate to theexpansion member 130, and theexpansion member 130 is positioned at a longitudinal position in thepassage 13 of theduct 12 that corresponds to the longitudinal position of themold contour 34 of themold collar 20, for example, as shown inFIGS. 10 and 11 . Thus, aformation portion 16 of theduct 12, i.e., theportion 16 of theduct 12 that is to be thermoplastically formed to make the bead, is disposed between theexpansion member 130 and themold contour 34 of themold collar 20, and therod heaters 120 are positioned proximate to and generally aligned with theformation portion 16 of theduct 12. - The
rod heaters 120 can be connected to apower supply 124, and theouter heater 50 can be connected to thepower supply 124 or a different source of power. Theheaters formation portion 16 of theduct 12 is heated to a formation temperature, such as a temperature higher than the glass transition temperature of thethermoplastic duct 12. For example, in one embodiment, theduct 12 is formed of a composite thermoplastic material comprising PEI reinforced with Kevlar® aramid and has a glass transition temperature of about 417° F. The duct can be formed at temperature less than the glass transition temperature, for example, about 350° F., but preferably is formed at higher temperatures to minimize stress on the reinforcing Kevlar® aramid. For example, in one advantageous embodiment, theduct 12 is formed at a temperature of between about 460° F. and 480° F., for a hold or processing time of between about 20 and 45 minutes. - Before or concurrently with the heating of the
formation portion 16 of theduct 12, theexpansion member 130 is expanded radially to urge theformation portion 16 of theduct 12 against themold contour 34. For example, a tightening adjustment of thenuts 109, illustrated byFIG. 11 relative toFIG. 10 , results in the radially outward expansion of theexpansion member 130. As shown, the tightening of thenuts 109 advances thesecond portion 96 of theinner support structure 90 into theaperture 102 of thefirst portion 94, thereby compressingexpansion member 130 longitudinally and expanding theexpansion member 130 radially against theduct 12. While theduct 12 is at the formation temperature, theexpansion member 130 urges theformation portion 16 against themold contour 34 and thermoplastically forms theformation portion 16 to the desired shape of theduct 12, which defines a bead in this embodiment. After processing at the formation temperature, theduct 12 can be at least partially cooled in the formingapparatus 10, for example, to a temperature less than the glass transition temperature. - In another embodiment of the present invention, illustrated in
FIGS. 12 and 13 , aninner support structure 140 comprises a single structure that defines achannel 142. Disposed in thechannel 142 is an expansion member, which is an elastomericinflatable bladder 144 defining at least oneinternal chamber 146. Theinflatable bladder 144 is configured to receive a fluid, such as air, into theinternal chamber 146 and thereby be expanded radially outwards. Thus, theinner support structure 140 can be positioned within thepassage 13 of theduct 12, and theduct 12 can be positioned in themold collar 20,outer heater 50, andholder 60 as described above in connection withFIG. 1 . A fluid source (not shown) can be fluidly connected to theinflatable bladder 144, for example, via thefluid line 146, andheaters 148, similar to theheaters 120 described above, can be connected to a power supply (not shown), for example, viawires 152. Theheaters 148 can be used to heat theduct 12, and theinflatable bladder 144 can be used to urge theformation portion 16 of theduct 12 against themold contour 34 and thereby thermoplastically form theformation portion 16 to the desired shape of theduct 12. - Although the forming
apparatus 10 is illustrated in the foregoing figures as a bead forming apparatus, theapparatus 10 can also be used to form other features by changing the configuration of themold contour 34. For example, the shape of themold contour 34 can define other continuous shapes extending arcuately around theinner surface 26 of themold collar 20, one or more non-continuous shapes, longitudinally extending shapes, and the like. Additionally, it is understood that the placement of theduct 12 in the formingapparatus 10 determines the position and, in part, the shape of the resulting feature. Therefore, theduct 12 can be inserted into the formingapparatus 10 according to the desired placement of the feature. For example, as shown inFIG. 10 , thefirst portion 94 of theinner support structure 90 is wider than theduct 12, and theduct 12 does not extend through thefirst portion 94 but rather is inserted to abut thefirst portion 94. Theduct 12 can also be inserted to a lesser extent, i.e., so that theduct 12 does not abut thefirst portion 94. Alternatively, thefirst portion 94 of theinner support 90 can fit within thepassage 13 of theduct 12 so that theduct 12 can extend, for example, to thefirst end 22 of themold collar 20, or even beyond themold collar 20. Thus, theinner support structure 90,mold collar 20, or an additional component of the formingapparatus 10 can function as a placement reference for theduct 12 so that theformation portion 16 of theduct 12 is positioned proximate to themold contour 34 and the feature is imparted onto theduct 12 at the desired location. Further, the positioning of theduct 12 in the formingapparatus 10 can affect the shape of the feature if theduct 12 is inserted such that theformation portion 16 occurs at the end of theduct 12 and only part of the feature is imparted onto theduct 12. For example, themold contour 34 shown inFIG. 5 , which typically forms thebead 14 on theduct 12, can also be used to form a short, outwardly flared, or bell shaped, feature by inserting theduct 12 so that theduct 12 extends only partially through themold contour 34 and theformation portion 16 occurs at the end of theduct 12. - A bell feature can also be formed according to the present invention using a forming
apparatus 150 such as the one shown inFIG. 14 . The formingapparatus 150 includes abase structure 152 that supports amandrel 160 and aclamping mechanism 170. Themandrel 160 is configured within theclamping mechanism 170 such that theduct 12 can be inserted therebetween. As shown inFIG. 15 , themandrel 160 defines anouter surface 162 that tapers from a first diameter d1 to a second, smaller diameter d2. Preferably, theduct 12 corresponds to the second diameter d2 and at least a portion of the duct can be configured to correspond to the larger first diameter d1. For example, as shown inFIG. 15A , theduct 12 can include aninterface portion 17 defined by unjoined and overlappinglongitudinal edges duct 12, e.g., a portion of theedges duct 12 to be inserted onto themandrel 160 and configured, at least partially, to the first diameter d1. - The mandrel includes a
heater 164 disposed in the wall of themandrel 160, though in other embodiments, theheater 164 can instead be positioned within acentral bore 166 of themandrel 160 or otherwise located in theapparatus 150. Theclamping mechanism 170 at least partially surrounds themandrel 160, and theduct 12 can be inserted axially into theapparatus 150, e.g., from the right inFIG. 15 , so that thepassage 13 of theduct 12 receives themandrel 160, and theduct 12 is retained tightly between theclamping mechanism 170 and themandrel 160. Thebase structure 152, theclamping mechanism 170, and themandrel 160 can be formed of any material with sufficient strength for supporting theduct 12 during processing, for example, aluminum, steel, titanium, and alloys thereof. - Preferably, the
inner surface 174 of theclamping mechanism 170 is defined by anelastomeric layer 176 such that theelastomeric layer 176 can be urged radially toward theduct 12 and retained between theclamping mechanism 170 and themandrel 160. Theheater 164 is configured to heat theduct 12 to a formation temperature, e.g., the glass transition temperature, and theelastomeric layer 176 preferably can be expanded to urge theduct 12 againstouter surface 174 of the mandrel. For example, theelastomeric layer 176 can comprise a heat expandable material that is axially restrained byend plates 178. With theduct 12 positioned in the formingapparatus 150, theheater 164 can be used to heat theformation portion 16 of theduct 12 to a formation temperature and heat the heat expandableelastomeric layer 176. Theelastomeric layer 176 expands radially and forces theduct 12 against themandrel 160. Thus, theduct 12 is thermoplastically formed to the shape of theouter surface 162 of themandrel 160, for example, thebell 15. In other embodiments, theelastomeric layer 176 can instead comprise an inflatable member similar to theinflatable bladder 144 described above. Theelastomeric layer 176 can also comprise a solid elastomer, and the formingapparatus 150 can include a mechanism for compressing the elastomer, for example, in the axial direction, to thereby expand the elastomer radially inwards. Additionally, theinterface portion 17 of theduct 12 can be heated to at least the glass transition temperature and thelongitudinal edges elastomeric layer 176 as described in U.S. application Ser. No. ______, titled “Consolidation Joining of Thermoplastic Laminate Ducts.” - According to another embodiment of the present invention, an
alternative forming apparatus 200, illustrated inFIGS. 16-19 , can be used to at least partially encapsulate theduct 12, heat theduct 12 to a forming temperature, and form theduct 12 against aninner mandrel 204. As shown inFIG. 17 , theinner mandrel 204 has anouter surface 206 that corresponds to the desired shape of theduct 12. In the illustrated embodiment, theouter surface 206 defines a bell shape, though other mold contours and shapes can similarly be provided including beads, ribs, channels, and the like.Bores 208 in theinner mandrel 204 are configured to receive rod orcartridge heaters 210, which are connected to apower supply 212, and generate resistive heat. Theinner mandrel 204 is inserted into theduct 12 as shown inFIG. 18 , and anelastomeric layer 214 is disposed over theduct 12. Theelastomeric layer 214 preferably is formed of a heat resistant material that elastically expands when heated, and can be preformed to a hollow cylindrical shape as shown. Anouter mandrel 216, which can comprise separable sections as shown inFIG. 19 , is then configured to surround theelastomeric layer 214. Theouter mandrel 216 is secured in abase support structure 218, as shown inFIG. 16 , which includesend plates 220, that are secured bybolts 222 or other fasteners. Preferably, theinner mandrel 204 is formed of a thermally conductive material, such as aluminum, steel, titanium, or alloys thereof, to conduct heat radially outward from theheaters 210 to theduct 12. Theouter mandrel 216 andbase support structure 218 are preferably sufficiently rigid to support theduct 12 during processing, and theelastomeric layer 214 and/or theouter mandrel 216 can be thermally insulative to reduce heat loss from the formingapparatus 200. - During operation, the
heaters 210 are connected to thepower supply 212 and heat the duct to the formation temperature. Theelastomeric layer 214 expands radially between theouter mandrel 216 and theduct 12, and preferably provides sufficient expansive force at the formation temperature to urge theduct 12 against theouter surface 206 of theinner mandrel 204. Additionally, theinterface portion 17 of theduct 12 can be heated above the glass transition temperature, and theelastomeric layer 214 can consolidation join theedges FIG. 15 . After a holding period at the formation temperature, theduct 12 can be at least partially cooled in the formingapparatus 200, for example, to a temperature less than the glass transition temperature. - The
clamping mechanism 170 and theouter mandrel 216 of theapparatuses elastomeric layers elastomeric layers elastomeric layer elastomeric layer elastomeric layer duct 12. - Alternatively, heat shrinkable
tape 230 can be used to configure theduct 12 to the desired configuration. As shown inFIG. 20 , a forming apparatus 200 a can be configured by positioning a rigidinner support structure 204 a, similar to theinner mandrel 204, longitudinally in thepassage 13 of theduct 12 so that anouter surface 206 a of thesupport structure 204 corresponds to theformation portion 16 of theduct 12. For example, theouter support surface 206 a can define a bell section, as shown inFIG. 20 , a bead, or the like. The heat shrinkabletape 230 is disposed circumferentially around theformation portion 16 of theduct 12, and thetape 230 can be disposed in one or more layers on theduct 12. In operation, thetape 230 and theduct 12 can be heated byheaters 210 a, which are connected to apower supply 212 a. Preferably, thetape 230 is configured to shrink when heated to the formation temperature of theduct 12 so that thetape 230 contracts in length and urges theformation portion 16 of theduct 12 radially inward against thesupport structure 204 a. Further, as shown inFIG. 20 , the forming apparatus 200 a can include aconsolidation joining head 232, which extends longitudinally and is adapted to be adjusted radially inward against theinterface portion 17 of theduct 12, i.e., in a direction indicated byreference numeral 240. Thehead 232 is preferably configured to urge theinterface portion 17 against thesupport structure 204 a and heat theinterface portion 17 to at least a glass transition temperature of theduct 12, thereby consolidation joining theedges interface portion 17, as provided in U.S. application Ser. No. ______, titled “Consolidation Joining of Thermoplastic Laminate Ducts.” Thehead 232 can comprise numerous types of heaters, for example, a flexible heater disposed on an elastomeric block, as discussed in U.S. application Ser. No. ______, titled “Preforming Thermoplastic Ducts,” filed concurrently herewith, the entirety of which is incorporated by reference.” - While the above forming
apparatuses apparatus FIG. 21 illustrates a formingapparatus 10 a similar to the formingapparatus 10 above. The formingapparatus 10 a includes at least onehydraulic actuator 40 for actuating diehalves mold collar 20 described previously, the die halves 30 a, 30 b define amold contour 34 a, which corresponds to a desired configuration of theduct 12. The die halves 30 a, 30 b also support a plurality ofheaters 120 a, which are connected to apower supply 124 a and heat theduct 12 during processing. Thefirst actuator 40 is configured to adjust at least one of the die halves 30 a, 30 b to an open position relative to aninner support structure 90 a so that aduct 12 can be inserted into the formingapparatus 10 a and to a closed position so that theduct 12 can be retained between the die halves 30 a, 30 b and theinner support structure 90 a. A second actuator (not shown) is configured to adjust afirst portion 94 a and/or a second portion (not shown) of theinner support structure 90 a to thereby expand anexpansion member 130 a, as described above in connection withFIGS. 10 and 11 . Similarly, actuators can be used to control other functions of the formingapparatuses - The
duct 12 can be formed from a preform (not shown) comprising a flat sheet of thermoplastic laminate, which defines connection features for connecting spuds, brackets, and the like to theduct 12. The preform can define a geometric pattern that corresponds to a desired shape or configuration of theduct 12, and the geometric pattern can be determined by projecting the desired shape of theduct 12 onto a flat laminate sheet. Methods and apparatuses for forming preforms and for determining geometric patterns that correspond to ducts are provided in U.S. application Ser. No. ______, titled “Thermoplastic Laminate Duct,” filed concurrently herewith, the entirety of which is incorporated herein by reference. It is also appreciated that marks can be provided on the preform, for example, to accurately identify the location of post-formed features such as bead and bells or to facilitate the manufacture or assembly of the ducts, as also provided in U.S. application Ser. No. ______, titled “Thermoplastic Laminate Duct.” - The preform can be bent, or preformed, to the desired shape of the duct and longitudinal ends of the preform can be joined to form the duct. Methods and apparatuses for configuring preforms to the bent, or preformed, configuration are provided in U.S. application Ser. No. ______, titled “Preforming Thermoplastic Ducts.” Methods and apparatuses for consolidation joining preforms to form ducts are provided in U.S. application Ser. No. ______, titled “Consolidation Joining of Thermoplastic Laminate Ducts.”
- Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
Claims (18)
1. A method of thermoplastically forming a contour in a thermoplastic duct, the method comprising:
providing a thermoplastic duct between a collar and an inner support structure;
heating at least a formation portion of the duct to at least a formation temperature; and
urging an expansion member against the duct to thermoplastically form the formation portion of the duct radially against a mold contour defined by one of the collar and inner support structure.
2. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , wherein said providing step comprises providing a cured thermoplastic duct formed of a reinforced thermoplastic composite material.
3. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , wherein said heating step comprises heating the formation portion of the duct to a temperature of at least a glass transition temperature.
4. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , wherein said urging step comprises expanding the expansion member radially outward against the formation portion of the duct to urge the formation portion against the collar.
5. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 4 , wherein said expanding step comprises adjusting a longitudinal width of a channel to compress the expansion member in the longitudinal direction and expand the expansion member radially outward.
6. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 4 , wherein said urging step comprises delivering fluid to an inflatable bladder to inflate the bladder and expand the bladder radially outward against the formation portion of the duct.
7. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , wherein said urging step comprises expanding the expansion member radially inward against the formation portion of the duct to urge the formation portion against the inner support structure.
8. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , wherein said urging step comprises heating the expansion member to expand the expansion member radially to form the formation portion of the duct.
9. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , further comprising separably adjusting at least one portion of the collar to remove the duct therefrom.
10. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , wherein said heating step comprises electrically energizing at least one resistive heater to generate heat and conducting heat from the at least one heater to the formation portion of the duct.
11. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , further comprising, subsequent to said heating step and at least partially concurrent to said urging step, cooling the joint to a temperature at least less than a glass transition temperature.
12. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , further comprising providing the collar and the inner support structure, the collar extending longitudinally from a first end to a second end and having an inner surface extending at least partially between the first and second ends, the inner surface defining a cavity, the inner support structure extending longitudinally in the cavity and having an outer surface opposing the inner surface of the collar, the collar defining a mold contour, the expansion member being formed of an elastomeric material, the inner support structure defining a channel for receiving the expansion member, and a width of the channel being adjustable in the longitudinal direction of the collar to compress the expansion member in the longitudinal direction and urge the expansion member radially toward the mold contour such that the expansion member is configured to urge a formation portion of the duct against the mold contour and thereby thermoplastically form the duct.
13. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 12 wherein said heating step comprises providing a plurality of heaters extending at least partially through the inner support structure and configured to heat a formation portion of the duct to at least a formation temperature.
14. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 , further comprising providing the inner support structure, the inner support structure being a rigid structure extending longitudinally in a cavity of the collar and including first and second portions, the first portion defining a face having an aperture configured to at least partially and longitudinally receive the second portion, and at least one heater extending at least partially through the inner support structure and configured to be disposed within the passage of the duct.
15. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 wherein said heating step comprises heating the duct with a plurality of heaters extending at least partially through said inner support structure.
16. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 1 wherein said heating step comprises heating the duct with at least one heater positioned radially outside the collar and configured to radiate heat radially inward to the duct.
17. A method of thermoplastically forming a contour in a thermoplastic duct, the method comprising:
configuring a rigid inner support structure to extend longitudinally in a passage of the duct such that a mold contour defined by an outer surface of the inner support structure and corresponding to a desired configuration of the duct is located proximate to a formation portion of the duct;
disposing heat shrinkable tape circumferentially around the formation portion of the duct; and
heating the heat shrinkable tape and at least a formation portion of the duct to at least a formation temperature, such that the tape contracts radially inward urging the formation portion of the duct radially against the mold contour and thermoplastically forming the duct.
18. A method of thermoplastically forming a contour in a thermoplastic duct according to claim 17 , further comprising adjusting a consolidation joining head radially inward against an interface portion of the duct defined by longitudinal edges of the duct to urge the interface portion against the inner support and heating the interface portion to at least a glass transition temperature, thereby consolidation joining the interface portion.
Priority Applications (1)
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US11/533,560 US20070013105A1 (en) | 2002-08-09 | 2006-09-20 | Post-Forming of Thermoplastic Ducts |
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Application Number | Priority Date | Filing Date | Title |
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US10/215,780 US7128558B2 (en) | 2002-08-09 | 2002-08-09 | Post-forming of thermoplastic ducts |
US11/533,560 US20070013105A1 (en) | 2002-08-09 | 2006-09-20 | Post-Forming of Thermoplastic Ducts |
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US10/215,780 Division US7128558B2 (en) | 2002-08-09 | 2002-08-09 | Post-forming of thermoplastic ducts |
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US10830188B2 (en) | 2015-09-25 | 2020-11-10 | Ford Global Technologies, Llc | Evaporative emissions testing using inductive heating |
Also Published As
Publication number | Publication date |
---|---|
US7128558B2 (en) | 2006-10-31 |
EP1388409B1 (en) | 2011-10-26 |
CA2434957A1 (en) | 2004-02-09 |
CA2434957C (en) | 2007-09-11 |
EP1388409A2 (en) | 2004-02-11 |
US20040026819A1 (en) | 2004-02-12 |
EP1388409B2 (en) | 2022-08-03 |
ES2372596T3 (en) | 2012-01-24 |
EP1388409A3 (en) | 2004-05-19 |
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