MODULAR COVER FOR A MOULDING TOOL

Abstract

A modular cover is provided to cover a molding tool, in which the cover comprises a plurality of plates configured to be coupled together to cover at least a portion of the surface of the molding tool, a fastening arrangement configured to fasten the plurality of plates to the molding tool, in which each of the plurality of plates has at least one coating of reflective material. A system and a method for manufacturing a structural element are also provided.

Claims

1-15. (canceled)

16. A modular cover for a molding tool, said modular cover comprising: a plurality of plates configured to be coupled together to cover at least a portion of a surface of the molding tool, fastening means configured to fasten the plurality of plates to the molding tool, wherein each of the plurality of plates has at least one coating of reflective material.

17. The modular cover as claimed in claim 16, wherein the fastening means include at least one screw.

18. The modular cover as claimed in claim 16, wherein the fastening means include at least one latch.

19. The modular cover as claimed in claim 16, wherein each of the plurality of plates has at least one metal or polymer sheet.

20. A system for manufacturing a structural element that includes: a molding tool that includes: a mold configured to receive an initial material, a heater to apply a thermal cycle to the initial material inside the mold, and a modular cover as claimed in claim 16.

21. The system as claimed in claim 20, additionally comprising: injection means for injecting polymer material into the mold, and pressure means for applying pressure to the polymer material inside the mold.

22. The system as claimed in claim 21, wherein the pressure means include a press.

23. The system as claimed in claim 22, wherein at least one plate of the plurality of plates is in contact along a surface of the plate with a surface of the press.

24. The system as claimed in of claim 20, wherein the heater includes a plurality of electrical resistors.

25. The system as claimed in claim 20, wherein at least one plate of the plurality of plates is in contact along a surface of the plate with a surface of the mold.

26. The system as claimed in claim 20, in which the plurality of plates completely covers a surface of the mold.

27. A method for manufacturing a structural element that includes the following steps: a) providing a system as claimed in claim 20, and an initial material, b) placing the initial material inside the mold, c) covering at least a portion of an outer surface of the mold with the modular cover, and d) applying a thermal cycle to the material inside the mold.

28. The manufacturing method as claimed in claim 27, in which the initial material is a reinforcing material and the structural element is a preform made of reinforcing material.

29. The manufacturing method as claimed in claim 27, in which: the initial material is a preform made of reinforcing material, the structural element is an element made of composite material, the method also includes injecting polymer material into the mold, and the thermal cycle is applied to the preform made of reinforcing material and to the polymer material contained in the mold.

30. The manufacturing method as claimed in claim 29, in which: the system includes pressure means, and the method also includes: applying pressure to the material inside the mold, and covering at least a portion of an outer surface of the pressure means with the modular cover before applying the thermal cycle and applying pressure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0059] These and other features and advantages of the invention are further clarified in the detailed description below of a preferred embodiment, given exclusively by way of illustrative and non-limiting example with reference to the attached figures.

[0060] FIGS. 1a-c show a first embodiment of the cover according to the invention, in which the plurality of plates partially covers a molding tool.

[0061] FIGS. 2a-c show a second embodiment of the cover according to the invention, in which the plurality of plates completely covers the lateral surface of an RTM mold.

[0062] FIG. 3 shows a cross-section of the cover positioned away from the surface of the molding tool, and shows the operating mechanism thereof schematically.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0063] FIGS. 1a-c show a schematic example of use of an embodiment of the modular cover (1) according to the invention, in which the cover (1) is fastened to a mold (2.1) that is heated to shape preforms made of reinforcing material.

[0064] In particular, FIG. 1a shows a metal mold (2.1) used to shape preforms made of reinforcing material, for example carbon fiber, by applying heat to the reinforcing material.

[0065] In this embodiment, the mold (2.1) has a quadrangular prism structure. The upper base of the mold (2.1) has a grooved shape formed by bars (2.2) of square section that extend parallel to the longitudinal axis of the body of the mold (2.1). Thermoelectric resistors are arranged on the inner face of the bars (2.2) and transmit heat to the bars. The bars then transfer this heat to the reinforcing material to enable the reinforcing material to be molded until a preform with the final desired shape has been obtained.

[0066] The conductivity and thermal emissivity of the metal body of the mold (2.1) causes most of the generated heat to be transmitted to the external atmosphere outside the mold (2.1) through the surface thereof that is not in contact with the reinforcing material.

[0067] FIG. 1b shows an exemplary modular cover (1) in an uncoupled arrangement, i.e., in which the different plates (1.1, 1.2, 1.3) that formed the cover (1) are separated from one another and from the mold (2.1). The cover (1) is designed geometrically to be coupled to the mold (2.1) shown in FIG. 1a . For this purpose, the modular cover (1) is made up of the plates (1.1, 1.2, 1.3), which in this case have three different geometries to enable each plate to fit and be coupled to a specific surface of the mold (2.1). Thus, the lateral plates (1.1, 1.2) are coupled structurally to the lateral surfaces of the mold (2.1), and the geometry of the top plate (1.3) is designed to couple structurally with the grooved shape formed by the bars (2.2) on the upper base of the body of the mold (2.1). The cover can include additional plates to cover the other lateral surfaces of the mold (2.1).

[0068] FIG. 1c shows the exemplary modular cover (1) shown in FIG. 1b coupled to the mold (2.1) in FIG. 1a . To do so, the plates (1.1, 1.2, 1.3) are connected together using latches (3) and fastened to the mold (2.1), completely covering the upper surface of the mold and partially covering the lateral surface of the mold.

[0069] The plates (1.1, 1.2, 1.3) that form the exemplary embodiment of the modular cover (1) shown include a coating of reflective material (1.1.1) that prevents some of the heat generated for the thermal cycle required to shape the reinforcing material from leaking out of the mold via the surface of the mold (2.1).

[0070] Thus, essentially all of the thermal energy generated by the thermoelectric resistors on the inner surface of the bars (2.2) positioned on the upper base of the body of the mold (2.1) is concentrated on the inside of the cover (1).

[0071] FIGS. 2a-b respectively show an exemplary RTM molding tool (2) and a modular cover (1) comprising different plates (1.1, 1.2, 1.3, 1.4) designed to cover the lateral surface of the mold (2.1) once the plates (1.1, 1.2, 1.3) have been coupled to one another, setting the position thereof in relation to the mold in the RTM system. FIG. 2c shows an example of operation illustrating a system for curing composite material using RTM that includes a molding tool (2) and a cover (1) such as those shown in FIGS. 2a and 2b.

[0072] In particular, FIG. 2a schematically shows an exemplary RTM molding tool (2) that includes a metal mold (2.1) designed to contain a preform of reinforcing material and to be injected internally with polymer material, such as a thermostable resin. Furthermore, pressure means (2.3) in the form of a press are shown on the upper surface of the molding tool (2). The molding tool (2) also includes heating means (2.2) in the form of thermoelectric resistors, that are adhered to and distributed over the external lateral surface of the mold (2.1).

[0073] FIG. 2b shows an exemplary modular cover (1) according to the invention comprising four plates (1.1, 1.2, 1.3, 1.4) of different geometries. The plates (1.1, 1.2, 1.3, 1.4) are disconnected from one another and are not fastened to the molding tool (2). The cover (1) is designed geometrically to be coupled to the lateral surface of the mold shown in FIG. 2a. For this purpose, the plates (1.1, 1.2, 1.3, 1.4) that make up the modular cover (1) in this case have four different geometries to enable the plates to fit and be coupled to the lateral surfaces of the mold (2.1). Furthermore, the plates (1.1, 1.2, 1.3, 1.4) have indentations to enable the thermoelectric resistors (2.2) to be engaged on the lateral surface of the mold (2.1).

[0074] FIG. 2c shows the exemplary modular cover (1) shown in FIG. 2b coupled to the mold (2.1) of the RTM molding tool (2) shown in FIG. 2a. The plates (1.1, 1.2, 1.3, 1.4) cover the entire lateral surface of the mold (2.1).

[0075] The cover (1) may include a fifth plate to cover the press (2.3) of the molding tool (2), thereby additionally reducing the leakage of thermal energy to the outside of the mold (2.1).

[0076] FIG. 3 is a schematic illustration of the operating mechanism of the present invention. Flow lines (100) show the portion of the thermal energy generated for the thermal curing or molding process that leaks out of the mold from the surface of a portion of a section of mold (2.1) in contact with the external atmosphere, the energy not being used and representing an energy loss and a reduction in the efficiency of the process.

[0077] The flow lines (100) are reflected back towards the mold (2.1) following contact with the coating of reflective material (1.1.1) in the illustrated section of one of the plurality of plates (1.1) that make up the modular cover (1) according to the invention.

[0078] In this embodiment, the plate (1.1) of the cover (1) includes a sheet (1.1.2) of polymer or metal material adhered to the coating of reflective material (1.1.1). The figure uses the flow line (200) to schematically show the residual thermal energy of the thermal process that is lost through the sheet (1.1.2) and transmitted to the external atmosphere outside the mold.

[0079] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.