MOULDING APPARATUS

Abstract

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 fluidcomprising an upper impression and a lower impression, said upper and lower impressions being configured to receive said first and second thermally conductive flanges.

Claims

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 a 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 press comprising a mold thermally conductive and thermoregulated by a heat transfer fluid, D. Preheating the thermally conductive flanges through the mold in said 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 press comprising a mold thermally conductive and thermoregulated by a heat transfer fluid, I. Cooling the thermally conductive flanges in said 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 50 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 10.10.sup.6 and 60.10.sup.6 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.Math.m.sup.?1.Math.K.sup.?1 and said mold thermally conductive and thermoregulated by a heat transfer fluid has a thermal conductivity greater than 30 W.Math.m.sup.?1.Math.K.sup.?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 50 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 10.10.sup.6 and 60.10.sup.6 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.Math.m.sup.?1.Math.K.sup.?1 and said mold thermally conductive and thermoregulated by a heat transfer fluid has a thermal conductivity greater than 30 W.Math.m.sup.?1.Math.K.sup.?1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0057] The present disclosure will be better understood, thanks to the description below, which relates to one or more embodiments according to the present disclosure, given by way of non-limiting examples and explained with reference to the appended schematic drawings, in which:

[0058] FIG. 1 is an overview of a system for manufacturing thermoplastic composites according to the present disclosure,

[0059] FIG. 2 is a side view of a system for manufacturing thermoplastic composites according to the present disclosure,

[0060] FIG. 3 is a schematic view of the method for manufacturing thermoplastic composites according to the present disclosure,

[0061] FIG. 4 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure,

[0062] FIG. 5 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure,

[0063] FIG. 6 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure,

[0064] FIG. 7 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure,

[0065] FIG. 8 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure,

[0066] FIG. 9 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure,

[0067] FIG. 10 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure,

[0068] FIG. 11 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure,

[0069] FIG. 12 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure and

[0070] FIG. 13 is an overview of part of the method for manufacturing thermoplastic composites according to the present disclosure.

DETAILED DESCRIPTION

[0071] FIGS. 1 and 2 illustrate a system 1 for manufacturing thermoplastic composites comprising: [0072] A molding apparatus 2 and [0073] A press 3 comprising an upper press platen 31 and a lower press platen 32.

[0074] The molding apparatus 2 comprises a first thermally conductive flange 21 and a second thermally conductive flange 22, said first 21 and second 22 thermally conductive flanges delimiting a cavity configured to receive thermoplastic pre-impregnated textiles. The first 21 and second 22 thermally conductive flanges have a thermal conductivity greater than 30 W.Math.m.sup.?1.Math.K.sup.?1 and preferably greater than 49 or greater than 55 W.Math.m.sup.?1.Math.K.sup.?1

[0075] The first 21 and second 22 thermally conductive flanges are for example made of black oxide coated steel, aluminum or thermoset composite. Preferably, said first and second thermally conductive flanges are made of black oxide coated steel, which has the effect of increasing the thermal conductivity.

[0076] The molding apparatus 2 further comprises a thermoregulated and thermally conductive mold 23 comprising an upper impression 24 and a lower impression 25 and having a thermal conductivity greater than 30 W.Math.m.sup.?1.Math.K.sup.?1, said upper 24 and lower 25 impressions being configured to receive said first 21 and second 22 thermally conductive flanges.

[0077] For example, the first 21 and second 22 thermally conductive flanges have a thickness comprised between 1 and 15 mm. Thus, the thermally conductive flanges are light and have an improved thermal conductivity.

[0078] The first 21 and second 22 thermally conductive flanges may comprise removable assembly means. For example, the removable assembly means are stop screws 26.

[0079] The thermoregulated and thermally conductive mold 23 is preferably made of steel. The thermoregulated and thermally conductive mold 23 is preferably regulated through a heat transfer fluid, for example water.

[0080] The upper impression 24 of the thermoregulated and thermally conductive mold 23 is fastened on the upper press platen 31 of the press 3 and the lower impression 25 of the thermoregulated and thermally conductive mold 23 is fastened on the lower press platen 32. The first 21 and second 22 thermally conductive flanges are removable, that is to say independent of the thermoregulated and thermally conductive mold 23 and of the press 3.

[0081] In this example, the system 1 comprises a vacuum device 11.

[0082] In this example, the system 1 further comprises a transfer frame 12 which makes it possible to transfer the first 21 and second 22 thermally conductive flanges, lateral guide supports 13 on which are fastened guide rails 14 which make it possible to guide the first 21 and second 22 thermally conductive flanges and the transfer frame 12.

[0083] The method for manufacturing thermoplastic composites using the system 1 for manufacturing thermoplastic composites comprises a step A) in which thermoplastic pre-impregnated textiles comprising fibers and a thermoplastic matrix are provided.

[0084] FIGS. 3 and 4 illustrate step B) in which the thermoplastic pre-impregnated textiles 4 are inserted into the first 21 and second 22 thermally conductive flanges. For this purpose, the thermoplastic pre-impregnated textiles 4 may be deposited on the second thermally conductive flange 22. The first flange 21 may then be deposited on the second thermally conductive flange 22 so as to delimit a cavity configured to receive the thermoplastic pre-impregnated textiles 4. The first 21 and second 22 thermally conductive flanges may then be assembled with stop screws 26 (FIG. 5).

[0085] For example, in step A), the thermoplastic pre-impregnated textiles 4 comprise fibers chosen from: short or continuous fibers, natural fibers, organic or mineral fibers. For example, the fibers are chosen from: basalt fibers, carbon fibers, glass fibers. For example, in step A), the thermoplastic matrix is composed of: polyolefins, polycarbonates, polyamides, polystyrenes, polyesters and/or polyaryletherketones. For example, thermoplastic matrix made of polyphenylene sulfide, thermoplastic matrix made of polyethylene, thermoplastic matrix made of poly(ethylene terephthalate).

[0086] FIG. 6 illustrates step C) in which the first 21 and second 22 thermally conductive flanges are transferred into the press 3. For this purpose, the first 21 and second 22 thermally conductive flanges being disposed on the rails 14.

[0087] FIGS. 3 and 7 illustrate step D) in which the first 21 and second 22 thermally conductive flanges are preheated through the mold 23 in said press 3. The preheating of the mold 23 may be carried out by convection or by conduction at a temperature comprised between 50 and 150? C. and for example at a temperature of 100? C. The preheating may be carried out for 1 to 10 min and for example, for 5 min.

[0088] FIGS. 3 and 7 also illustrate step E) in which the first 21 and second 22 thermally conductive flanges are pressed. The pressing may be carried out at a pressure comprised between 10.10.sup.6 and 60.10.sup.6 Pa and for example at a pressure equal to 15.10.sup.6 Pa.

[0089] FIG. 7 also illustrates step M) which may be carried out after step E) including the vacuuming of the first 21 and second 22 thermally conductive flanges using the vacuuming device 11. For example, a thermoresistant seal is inserted between said first 21 and second 22 thermally conductive flanges. The seal may have a compression factor comprised between 0.1 and 3 mm and for example a compression factor of 1.5 mm.

[0090] FIG. 8 illustrates the opening of the press 3. The first 21 and second 22 thermally conductive flanges may then be disposed on the transfer frame 12 (FIG. 1). In a step F), the first 21 and second 22 thermally conductive flanges are transferred into an Infra-Red IR oven.

[0091] FIGS. 3 and 9 illustrate step G) in which the first 21 and second 22 thermally conductive flanges are heated in an Infra-Red IR oven. For example, the first 21 and second thermally conductive flanges are heated at the melting temperature of the thermoplastic matrix of the thermoplastic pre-impregnated textiles. The heating of the first 21 and second 22 thermally conductive flanges may be carried out for 5 to 15 min or for example for 8 min.

[0092] FIG. 10 illustrates the opening of the press 3. The first 21 and second 22 thermally conductive flanges may then be disposed on the transfer frame 12 (FIG. 1). In a step H), the first 21 and second 22 thermally conductive flanges are transferred into the press 3.

[0093] FIGS. 3 and 11 illustrate step I) in which the first 21 and second 22 thermally conductive flanges are cooled. For example, the first 21 and second 22 thermally conductive flanges are cooled at a temperature at least 10? C. lower than the glass transition temperature of the thermoplastic matrix. The cooling may be carried out for 1 to 10 min or for example for 6 min.

[0094] FIGS. 3 and 11 also illustrate step J) in which the first 21 and second 22 thermally conductive flanges are pressed. The pressing may be carried out at a pressure comprised between 10.10.sup.6 and 60.10.sup.6 Pa and for example at a pressure equal to 15.10.sup.6 Pa.

[0095] FIG. 11 also illustrates step M) which may be carried out after step J) including the vacuuming of the first 21 and second 22 thermally conductive flanges using the vacuuming device 11. For example, a thermoresistant seal is inserted between said first 21 and second 22 thermally conductive flanges. The seal may have a compression factor comprised between 0.1 and 3 mm and for example a compression factor of 1.5 mm.

[0096] FIG. 12 illustrates the opening of the press 3 when the cooling is complete.

[0097] FIG. 13 illustrates step K) in which the first 21 and second 22 thermally conductive flanges are extracted from the press 3. After removing the first thermally conductive flange 21, the thermoplastic composites 41 may be unmolded. For example, the thickness of the part made of thermoplastic composite is comprised between 1 and 50 mm, preferably between 1 and 10 mm and is for example 2 mm.

[0098] When implementing the method according to the present disclosure, two separate presses may be used during steps C) and H).

[0099] The molding apparatus according to the present disclosure facilitates the shaping of the thermoplastic pre-impregnated textiles. Furthermore, the energy efficiency of the method for manufacturing thermoplastic composites is improved. In addition, the removable thermally conductive flanges allow a better consolidation of the thermoplastic pre-impregnated textiles while facilitating the method for manufacturing thermoplastic composites. The method for manufacturing thermoplastic composites may be implemented on an industrial scale, particularly continuously. In addition, the first and second thermally conductive flanges and the thermoregulated and thermally conductive mold have compatible thermal expansions to ensure a mastery of the dimensions of the thermoplastic composites. Finally, the first and second thermally conductive flanges ensure an optimal heat transfer and guarantee a temperature homogeneity within them while maintaining an optimal quality of the thermoplastic composites.