Moulding apparatus
View Patent ↗The present disclosure concerns a molding apparatus including: a first thermally conductive flange and a second thermally conductive flange, said first and second thermally conductive flanges delimiting a cavity configured to receive thermoplastic pre-impregnated textiles, a mold thermally conductive and thermoregulated by a heat transfer fluid—comprising an upper impression and a lower impression, said upper and lower impressions being configured to receive said first and second thermally conductive flanges.
1 . A method for manufacturing thermoplastic composites using a system for manufacturing thermoplastic composites comprising:
a molding apparatus comprising a first thermally conductive flange and a second thermally conductive flange, said first and second thermally conductive flanges delimiting a cavity configured to receive thermoplastic pre-impregnated textiles, and a mold thermally conductive and thermoregulated by a heat transfer fluid comprising an upper impression and a lower impression, said upper and lower impressions being configured to receive said first and second thermally conductive flanges, and
at least one press comprising an upper press platen on which the upper impression of the thermoregulated and thermally conductive mold is fastened and a lower press platen on which the lower impression of the thermoregulated and thermally conductive mold is fastened
the method for manufacturing thermoplastic composites comprising the following steps:
A. Providing thermoplastic pre-impregnated textiles comprising fibers and a thermoplastic matrix,
B. Inserting the thermoplastic pre-impregnated textiles into first and second thermally conductive flanges,
C. Transferring the thermally conductive flanges into a first press of said at least one press comprising a mold thermally conductive and thermoregulated by a heat transfer fluid,
D. Preheating the thermally conductive flanges through the mold in said first press,
E. Pressing the thermally conductive flanges,
F. Transferring the thermally conductive flanges into an Infra-Red (IR) oven,
G. Heating the thermally conductive flanges under Infra-Red to fuse the thermoplastic matrix,
H. Transferring the thermally conductive flanges into a second press of said at least one press comprising a mold thermally conductive and thermoregulated by a heat transfer fluid, wherein the first press and the second press are the same press or separate presses,
I. Cooling the thermally conductive flanges in said second press,
J. Pressing the thermally conductive flanges in said press,
K. Extracting the thermally conductive flanges from said press and
L. Unmolding the thermoplastic composites.
2 . The method for manufacturing thermoplastic composites according to claim 1 , wherein in step D), the preheating of the mold is carried out by convection or by conduction.
3 . The method for manufacturing thermoplastic composites according to claim 1 , wherein in step D), the preheating of the mold is carried out at a temperature comprised between 5° and 150° C.
4 . The method for manufacturing thermoplastic composites according to claim 1 , wherein in steps E) and/or J), the pressing is carried out at a pressure comprised between 10 7 and 6.10 7 Pa.
5 . The method for manufacturing thermoplastic composites according to claim 1 , comprising a step M) carried out after step E) or J), including vacuuming the first and second thermally conductive flanges.
6 . The method for manufacturing thermoplastic composites according to claim 5 , wherein a seal is inserted between said first and second thermally conductive flanges.
7 . The method for manufacturing thermoplastic composites according to claim 1 , wherein in step G), the first and second thermally conductive flanges are heated at a melting temperature of the thermoplastic matrix of the thermoplastic pre-impregnated textiles.
8 . The method for manufacturing thermoplastic composites according to claim 1 , wherein in step I), the first and second thermally conductive flanges are cooled at a temperature at least 10° C. lower than a glass transition temperature of the thermoplastic matrix.
9 . The method for manufacturing thermoplastic composites according to claim 1 , wherein the thermoplastic pre-impregnated textiles comprise electronic components based on inorganic compounds or organic compounds.
10 . The method for manufacturing thermoplastic composites according to claim 1 , wherein said first and second thermally conductive flanges have a thermal conductivity greater than 30 W·m −1 ·K −1 and said mold thermally conductive and thermoregulated by a heat transfer fluid has a thermal conductivity greater than 30 W·m −1 ·K −1 .
11 . The method for manufacturing thermoplastic composite according to claim 1 , wherein said first and second thermally conductive flanges are made of black oxide coated steel, aluminum or thermoset composite.
12 . The method for manufacturing thermoplastic composites according to claim 1 , wherein said first and second thermally conductive flanges comprise removable assembly means.
13 . The method for manufacturing thermoplastic composites according to claim 2 , wherein in step D), the preheating of the mold is carried out at a temperature comprised between 5° and 150° C.
14 . The method for manufacturing thermoplastic composites according to claim 13 , wherein in steps E) and/or J), the pressing is carried out at a pressure comprised between 10 7 and 6.10 7 Pa.
15 . The method for manufacturing thermoplastic composites according to claim 14 , comprising a step M) carried out after step E) or J), including vacuuming the first and second thermally conductive flanges.
16 . The method for manufacturing thermoplastic composites according to claim 15 , wherein a seal is inserted between said first and second thermally conductive flanges.
17 . The method for manufacturing thermoplastic composites according to claim 16 , wherein in step G), the first and second thermally conductive flanges are heated at a melting temperature of the thermoplastic matrix of the thermoplastic pre-impregnated textiles.
18 . The method for manufacturing thermoplastic composites according to claim 17 , wherein in step I), the first and second thermally conductive flanges are cooled at a temperature at least 10° C. lower than a glass transition temperature of the thermoplastic matrix.
19 . The method for manufacturing thermoplastic composites according to claim 18 , wherein the thermoplastic pre-impregnated textiles comprise electronic components based on inorganic compounds or organic compounds.
20 . The method for manufacturing thermoplastic composites according to claim 19 , wherein said first and second thermally conductive flanges have a thermal conductivity greater than 30 W·m −1 ·K −1 and said mold thermally conductive and thermoregulated by a heat transfer fluid has a thermal conductivity greater than 30 W·m −1 ·K −1 .