PRODUCTION SYSTEM

Abstract

The present invention relates to at least one mold (2) produced by additive manufacturing method; at least one layer (3) (laminated) of resin-impregnated fabrics laid on an outer wall surface of the mold (2); at least one vacuum bag (4) which is placed to substantially cover the layer (3) and allows vacuuming; at least one furnace (5) which enables the layer (3) to be cured by heating, applies pressure to the layer (3) at a pressure value predetermined by the user, and into which the mold (2) is placed; at least one part (6) formed by curing the layers (3).

Claims

1. A production system comprising at least one mold produced by additive manufacturing method; at least one layer (laminate) of resin-impregnated fabrics laid on an outer wall surface of the mold; at least one vacuum bag which is placed to substantially cover the layer and allows vacuuming; at least one furnace which enables the layer to be cured by heating, applies pressure to the layer at a pressure value predetermined by the user, and into which the mold is placed; at least one part formed by curing the layers, wherein at least one additional vacuum bag enabling an inner wall surface of the mold to be vacuumed, and allowing the mold to be vacuumed without breaking such that the mold withstands the pressure inside the furnace during a curing process, thereby keeping the mold rigid; the mold which has a brittle structure so as to be removed from the cured part, and is removed from the part by the manufacturer by breaking.

2. A production system according to claim 1, wherein at least one reference direction (D) predetermined by the manufacturer, which is located on the mold so as to be noticed by the user; the mold which is broken along the reference direction (D) to be removed from the part.

3. A production system according to claim 1, wherein the mold which has substantially the same wall thickness as the part, is form-fitting with the part, and is produced by a 3D printer so as to have a geometric shape predetermined by the user.

4. A production system according to claim 1, wherein the mold which has a greater wall thickness in its flat-form areas than in its single curvature and/or double curvature areas, thus allowing to absorb the impacts to which the mold is exposed.

5. A production system according to claim 1, wherein the part obtained by removing excess edge of parts from the part by laser cutting.

6. A production system according to claim 1, wherein the mold having at least partially a hollow geometry and/or at least partially a cylindrical geometry.

7. A production system according to claim 1, wherein the mold made of a thermoplastic polyetherimide material such as Ultem.

8. A production system according to claim 1, wherein the mold having a thinner wall thickness than the part, thus applying more effective pressure on the part.

9. A production system according to claim 1, wherein at least one curvature edge with a wall thickness greater than the flat areas of the mold, and which allows to absorb the impacts to which the mold is exposed; at least one support element located on the curvature edge and increasing the strength of the mold.

10. A production system according to claim 1, wherein at least one additional mold produced integrally with the mold; the part produced integrally with a single curing step without requiring an additional curing step to assemble the mold and the additional mold.

11. A production system according to claim 1, wherein the additional vacuum bag integral with the vacuum bag.

12. A production system according to claim 1, wherein the mold and the part suitable for use in air and/or space vehicles.

13. A production system wherein the part which is produced by: producing the mold by additive manufacturing method; obtaining the layer (laminated) forming the outer wall surface of the mold by laying the fabrics on the mold; placing the vacuum bag on the layer, wherein the vacuum bag allows vacuuming by substantially covering the layer; vacuuming the inner wall surface of the mold by the additional vacuum bag; placing the mold and layer in the furnace, which has a temperature and/or pressure value predetermined by the user; applying pressure on the wall of the mold during curing by means of the additional vacuum bag, so that the mold is kept rigid without breaking; breaking the mold to remove the part from the mold.

Description

[0024] The production system realized to achieve the object of the present invention is illustrated in the attached drawings, in which:

[0025] FIG. 1 is an illustration of the mold and layer.

[0026] FIG. 2 is a schematic illustration of the production system.

[0027] FIG. 3 is a schematic illustration of the production system.

[0028] FIG. 4 is an illustration of the part formed after being treated in the furnace.

[0029] FIG. 5 is a schematic illustration of the production system.

[0030] FIG. 6 is a front and rear view of the mold.

[0031] All the parts illustrated in figures are individually assigned a reference numeral and the corresponding terms of these numbers are listed below: [0032] 1. Production System [0033] 2. Mold [0034] 3. Layer [0035] 4. Vacuum Bag [0036] 5. Furnace [0037] 6. Part [0038] 7. Additional Vacuum Bag [0039] 8. Curvature Edge [0040] 9. Support Element [0041] 10. Additional Mold [0042] (D) Direction

[0043] The production system (1) comprises at least one mold (2) produced by additive manufacturing method; at least one layer (3) (laminated) of resin-impregnated fabrics laid on an outer wall surface of the mold (2); at least one vacuum bag (4) which is placed to substantially cover the layer (3) and allows vacuuming; at least one furnace (5) which enables the layer (3) to be cured by heating, applies pressure to the layer (3) at a pressure value predetermined by the user, and into which the mold (2) is placed; at least one part (6) formed by curing the layers (3) (FIG. 1, FIG. 2, FIG. 3).

[0044] The production system (1) according to the invention comprises at least one additional vacuum bag (7) enabling an inner wall surface of the mold (2) to be vacuumed, and allowing the mold (2) to be vacuumed without breaking such that the mold (2) withstands the pressure inside the furnace (5) during a curing process, thereby keeping the mold (2) rigid; the mold (2) which has a brittle structure so as to be removed from the cured part (6), and is removed from the part (6) by the manufacturer by breaking (FIG. 4, FIG. 5, FIG. 6).

[0045] The production system (1) comprises at least one mold (2) produced by additive manufacturing method; at least one layer (3) (laminated) of resin-impregnated fabrics (prepreg) and plies (fabric layers) laid on the outer wall of the mold (2); at least one vacuum bag (4) laid on the mold (2) so as to substantially cover the layer (3) on the mold (2) wherein the vacuum bag (4) allows vacuuming to evacuate the air between the layer (3) and/or the ply and/or the air between the mold (2) and the layer (3); at least one furnace (5) which enables the layer (3) to be cured by heating, applies pressure to the layer (3) at a pressure value predetermined by the user in order to shape the layer (3), and into which the mold (2) is placed; at least one part (6) formed by curing the layers (3) in the furnace (5). The preform and/or laminated layer (3) is laid on the outer wall surface of the mold (2), thereby forming the outer wall of the mold (2). Layer (3) consists of plies.

[0046] The production system (1) comprises the vacuum bag (4) which is located to substantially cover the outer wall surface of the mold (2), and allows vacuuming to evacuate the air between the mold (2) and the layer (3) and/or the excess air in the layer (3) and/or the excess air in the plies and/or to shape the layer (3) and/or to distribute the resin in the layer (3) homogenously.

[0047] The production system (1) comprises at least one additional vacuum bag (7) which provides vacuuming of the inner wall surface of the mold (2), extends longitudinally along the inner wall of the mold (2), applies pressure to the mold (2) internally, allows the mold (2) to withstand the pressure it is exposed to in the oven (5) during and/or before curing, and keeps the mold (2) rigid since the mold (2) is vacuumed without breaking even though it has a brittle structure and the pressure inside and outside the mold (2) is balanced. Inner wall of the mold (2) is not in contact with the fabric, ply, layer (3) and the like. The layer (3) is wrapped around the outer surface of the mold (2). Since the outer surface of the mold (2) is vacuumed by the vacuum bag (4) and the inner wall of the mold (2) is vacuumed by the additional vacuum bag (7), internal pressure of the mold (2) and external pressure of the mold (2) are balanced. During a vacuuming process, shape of the mold (2) is substantially preserved. The mold (2) placed in the furnace (5) and the layer (3) surrounding the mold (2) provide the part (6) to be obtained after the curing process. The part (6) obtained is removed from the mold (2) by breaking the thin, brittle mold (2).

[0048] In an embodiment of the invention, the production system (1) comprises at least one reference direction (D) predetermined by the manufacturer, which is located on the mold (2) so as to be noticed by the user; the mold (2) which is broken along the reference direction (D) to be removed from the part (6). Since the mold (2) is broken according to the reference direction (D) lines extending from one end of the mold (2) to the other end thereof, the part (6) can be removed from the mold without substantially damaging the part (6). Also, the part (6) can be removed from the mold (2) more easily.

[0049] In an embodiment of the invention, the production system (1) comprises the mold (2) which has substantially the same wall thickness as the part (6), is form-fitting with the part (6), and is produced by a 3D printer so as to have a geometric shape predetermined by the user. For the part (6) which has the desired geometric shape to be produced, the mold (2) is produced with a 3D printer so as to be form-fittingly compatible with the part (6). Thanks to the mold (2) having substantially the same thickness as the part (6), the mold (2) exerts more effective pressure on the layer (3) and/or the part (6).

[0050] In an embodiment of the invention, the production system (1) comprises the mold (2) which has a greater wall thickness in its flat-form areas than in its single curvature and/or double curvature areas, thus allowing to absorb the impacts to which the mold (2) is exposed. The flat areas of the mold (2), which are more unstable and in need of structural support, have greater wall thickness than the other areas. In this way, the impacts to which flat parts of the mold (2) will be exposed can be absorbed. Mold (2) strength is increased.

[0051] In an embodiment of the invention, the production system (1) comprises the part (6) obtained by removing excess edge of parts (6) (EOP) from the part (6) by laser cutting. For the final part (6) obtained, the excess EOP (edge of part) areas on the part (6) are removed from the part (6) by cutting and/or by laser cutting.

[0052] In an embodiment of the invention, the production system (1) comprises the mold (2) having at least partially a hollow geometry and/or at least partially a cylindrical geometry. The production system (1) comprises the mold (2) having a hollow and/or cylindrical geometry, with one open end and/or at least one open end. Therefore, the parts (6) with eccentric geometrical shapes having this form can be vacuumed both internally and externally.

[0053] In an embodiment of the invention, the production system (1) comprises the mold (2) made of a thermoplastic polyetherimide material such as Ultem. The mold (2) can be used, which is a thermoplastic and/or thermoset material with a thin and brittle structure that can withstand high temperature values.

[0054] In an embodiment of the invention, the production system (1) comprises the mold (2) having a thinner wall thickness than the part (6), thus applying more effective pressure on the part (6). Because the mold (2) has a thinner form than the part (6) and/or the layer (3), the mold (2) applies more effective pressure to the part (6) and/or the layer (3) by means of the vacuum bag (4) and the additional vacuum bag (7).

[0055] In an embodiment of the invention, the production system (1) comprises at least one curvature edge (8) with a wall thickness greater than the flat areas of the mold (2), and which allows to absorb the impacts to which the mold (2) is exposed; at least one support element (9) located on the curvature edge (8) and increasing the strength of the mold (2). Since the curvature edges (8) on the mold (2) are exposed to impacts, the mold (2) strength is increased by the support element (9).

[0056] In an embodiment of the invention, the production system (1) comprises at least one additional mold (10) produced integrally with the mold (2); the part (6) produced integrally with a single curing step without requiring an additional curing step to assemble the mold (2) and the additional mold (10). In order to assemble the mold (2) and the additional mold (10), which have a complex geometry, a curing step is required again in the furnace (5).

[0057] However, thanks to the mold (2) and the additional mold (10), which are produced integrally by the additive manufacturing method, a solid part (6) is obtained without requiring an additional curing step in the furnace (5).

[0058] In an embodiment of the invention, the production system (1) comprises the additional vacuum bag (7) integral with the vacuum bag (4). Thus, vacuuming is provided with a single vacuum bag (4).

[0059] In an embodiment of the invention, the production system (1) comprises the mold (2) and the part (6) suitable for use in air and/or space vehicles. In this way, material selection can be made in accordance with flight standards.

[0060] In an embodiment of the invention, the production system (1) comprises the part (6) which is produced by: [0061] producing the mold (2) by additive manufacturing method; [0062] obtaining the layer (3) (laminated) forming the outer wall surface of the mold (2) by laying the fabrics on the mold (2); [0063] placing the vacuum bag (4) on the layer (3), wherein the vacuum bag (4) allows vacuuming by substantially covering the layer (3); [0064] vacuuming the inner wall surface of the mold (2) by the additional vacuum bag (7); [0065] placing the mold (2) and layer (3) in the furnace (5), which has a temperature and/or pressure value predetermined by the user; [0066] applying pressure on the wall of the mold (2) during curing by means of the additional vacuum bag (7), so that the mold (2) is kept rigid without breaking; [0067] breaking the mold (2) to remove the part (6) from the mold (2). The part (6) is produced by: [0068] producing the mold (2) by additive manufacturing method; [0069] obtaining the layer (3) (laminated) forming the outer wall surface of the mold (2) by laying the plies on the mold (2); [0070] placing the vacuum bag (4) on the layer (3), wherein the vacuum bag (4) allows vacuuming to the outer wall of the mold (2) so as to substantially cover the layer (3); [0071] vacuuming the inner wall surface of the mold (2) substantially simultaneously with the outer wall surface of the mold (2) by means of the additional vacuum bag (7); [0072] placing the mold (2) and layer (3) in the furnace (5), which has a temperature and/or pressure value predetermined by the user, and curing the layer (3); [0073] applying pressure on the wall of the mold (2) during curing by means of the additional vacuum bag (7), so that the mold (2) is kept rigid without breaking; [0074] breaking the mold (2) to remove the part (6) from the mold (2).