阅读说明：本技术 匹配的压缩模具设备及其制造方法 (matched compression mold apparatus and method of making same ) 是由 R·R·勒布朗 A·A·皮拉尔 C·G·麦克内利 于 2019-05-30 设计创作，主要内容包括：本发明涉及匹配的压缩模具设备及其制造方法。该设备包括增材制造的芯构件和增材制造的腔构件,芯构件和腔构件可以用于制造压缩成型部件,诸如飞行器内饰的热固性和/或热塑性塑料面板。该设备可以包括通用的框架结构,该框架结构被配置成支撑配置用于成型不同面板的不同的增材制造的芯构件和腔构件。增材制造的芯构件和腔构件可以由金属和/或聚合物材料制成。该设备可以包括诸如加热毯之类的加热机构,该加热机构被配置成充分地加热芯构件和腔构件以将工件成型为期望形状。(The invention relates to a matched compression mold apparatus and a method of making the same. The apparatus includes an additive manufactured core member and an additive manufactured cavity member that may be used to manufacture compression molded parts, such as thermoset and/or thermoplastic panels for aircraft interiors. The apparatus may include a universal frame structure configured to support different additive manufactured core and cavity members configured for molding different panels. The additively manufactured core member and cavity member may be made of metal and/or polymer material. The apparatus may include a heating mechanism, such as a heating blanket, configured to sufficiently heat the core member and the cavity member to form the workpiece into a desired shape.)

1. A matched compression mold apparatus, the apparatus comprising:

A first additively manufactured die component having a first intermediate portion configured to profile a first side of a workpiece;

A second additively-manufactured mold part having a second intermediate portion configured to profile onto a second side of the workpiece;

A heating mechanism configured to heat the first and second intermediate portions sufficiently to solidify the workpiece into a desired shape; and

A compression device configured to apply a force directing the first and second intermediate portions toward each other.

2. The apparatus of claim 1, wherein the first and second intermediate portions are comprised of a polymeric material.

3. The apparatus of claim 1, wherein the first and second intermediate portions are comprised of a metallic material.

4. The apparatus of claim 1, wherein the heating mechanism comprises: a first heating blanket connected to a bottom side of the first intermediate portion; and a second heating blanket connected to a top side of the second intermediate portion.

5. The apparatus of claim 1, wherein each mold part has a rigid frame structure configured to support interchangeable intermediate portions to mold differently shaped workpieces.

6. The apparatus of claim 1, wherein the first and second intermediate portions are configured to form an aircraft interior panel.

7. The apparatus of claim 1, wherein the first and second intermediate portions are configured for crush core molding of a honeycomb core thermoset sandwich composite panel.

8. The apparatus of claim 4, wherein the first and second intermediate sections and corresponding heating blankets are configured to heat the workpiece up to a temperature between 200 degrees Fahrenheit and 300 degrees Fahrenheit.

9. The apparatus of claim 1, wherein the compression device comprises a press configured to apply a pressure of at least 50psi that forces the intermediate portions toward one another.

10. The apparatus of claim 1, wherein the apparatus weighs less than 1000 pounds.

11. The apparatus of claim 1, wherein the apparatus weighs less than 500 pounds.

12. A matched compression mold apparatus, the apparatus comprising:

A core member;

a cavity member, the core member and the cavity member configured to cooperatively form opposing sides of a panel;

A first frame structure configured to support the core member;

A second frame structure configured to support the cavity member, wherein the first frame structure and the second frame structure are common, the core member and the cavity member being selectively installed in the respective frame structures and configured to form a specific panel shape.

13. The apparatus of claim 12, wherein the core member and the cavity member are manufactured by additive manufacturing.

14. The apparatus of claim 13, wherein the core member and the cavity member are made of a metallic material.

15. The apparatus of claim 13, wherein the core member and the cavity member are made of a polymeric material.

16. The apparatus of claim 12, the apparatus further comprising:

A compression device configured to apply a force directing the core member and the cavity member toward each other.

17. The apparatus of claim 12, the apparatus further comprising:

A first heating blanket connected to a bottom side of the core member; and

A second heating blanket connected to a top side of the cavity member.

18. A method of making a mating compression molding die, the method comprising the steps of:

Additive manufacturing a core member;

Additive manufacturing a cavity member;

Connecting a first heating element to the core member;

Connecting a second heating element to the cavity member; and

Installing the core member and the cavity member in a frame structure configured to form a workpiece.

19. The method of claim 18, wherein the frame structure is universal, the installing step comprising: different core and cavity members are interchanged in the frame structure to produce different panel structures.

20. The method of claim 18, wherein the core member and the cavity member are made of a metallic material or a polymeric material.

Technical Field

the present disclosure relates to systems and methods for manufacturing compression molding tools.

background

Compression molding systems are used to manufacture parts in various industries. For example, in aerospace applications, compression molding systems are widely used to manufacture aircraft interior panels made of thermoset materials. However, the compression molding apparatus components currently used to manufacture panels are typically very large and bulky, and thus the manufacturing processes involving these components can be inflexible, expensive, and inconvenient. For example, it is often difficult to move compression mold parts from one place to another and compress them in a press. In addition, the time and expense required to manufacture conventional compression mold apparatus is significant. Compression mold equipment that is lighter and requires less time and expense to manufacture is an important advantage for manufacturing aircraft interior panels and other objects.

Disclosure of Invention

The present disclosure provides systems, apparatuses, and methods relating to compressing mold components. In some embodiments, a matched compression mold apparatus comprises: a first die component of additive manufacturing having a first intermediate portion configured to shape a profile on a first side of a workpiece; a second die component of additive manufacturing having a second intermediate portion configured to profile a second side of the workpiece; a heating mechanism configured to heat the first and second intermediate portions sufficiently to form the workpiece into a desired shape; and a compression device configured to compress the first and second intermediate portions toward each other.

In some embodiments, a matched compression mold apparatus comprises: a core member and a cavity member configured to cooperatively form opposing sides of a panel; a first frame structure configured to support the core member; a second frame structure configured to support the cavity member, wherein the frame structure is universal, the core member and cavity member being selectively mounted in the respective frame structure and configured to shape a particular panel shape.

In some embodiments, a method of making a mating compression molding die comprises the steps of: additive manufacturing a core member; additive manufacturing a cavity member; connecting a first heating element to the core member; connecting a second heating element to the cavity member; and installing the core member and the cavity member in a frame structure configured to shape a workpiece.

The features, functions, and advantages can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and associated drawings.

Drawings

Fig. 1 is an isometric view of an illustrative aircraft interior sandwich panel according to aspects of the present disclosure.

Fig. 2 is a partially exploded view of the sandwich panel of fig. 1.

Fig. 3 is a schematic view of an illustrative compression mold apparatus according to aspects of the present disclosure.

Fig. 4 is an isometric view of an illustrative compression mold apparatus according to aspects of the present disclosure.

fig. 5 is a partially exploded view of the compression mold apparatus of fig. 4.

Fig. 6 is an isometric view of an illustrative intermediate portion of a compression mold component of the compression mold apparatus of fig. 4.

Figure 7 is a top view of a middle portion of the mold part of figure 6.

Fig. 8 is a front view of a middle portion of the mold part of fig. 6.

Fig. 9 is a cross-sectional view of the intermediate portion of the mold part of fig. 6 taken in the direction indicated in fig. 7.

fig. 10 is a cross-sectional view of the intermediate portion of the mold part of fig. 6 taken in the direction indicated in fig. 8.

Fig. 11 is an isometric view of an illustrative compression mold component of the compression mold apparatus of fig. 4.

Fig. 12 is an isometric view of another illustrative compression mold component of the compression mold apparatus of fig. 4.

fig. 13 is a schematic diagram depicting a press used in conjunction with the compression mold apparatus of fig. 4.

Fig. 14 is a flow chart depicting steps of an illustrative method of additive manufacturing.

Fig. 15 is a schematic diagram depicting an illustrative additive manufacturing device suitable for performing the method of fig. 14.

Fig. 16 is a flow chart depicting steps of an illustrative method of manufacturing a matched compression molding die in accordance with aspects of the present disclosure.

Fig. 17 is a flow chart depicting steps of an illustrative method of manufacturing a compression molded component in accordance with aspects of the present disclosure.

Detailed Description

Various aspects and examples of mating compression mold apparatuses with additive manufactured parts and related methods are described below and illustrated in related figures. Unless otherwise indicated, mating compression mold apparatus and/or various components thereof according to the present teachings may, but are not required to, comprise at least one of the structures, components, functions and/or variations described, illustrated and/or incorporated herein. Moreover, unless expressly excluded, process steps, structures, components, functions, and/or variations described, illustrated, and/or incorporated herein in connection with the present teachings can be included in other similar apparatus and methods including interchangeable between disclosed embodiments. The following description of various examples is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Additionally, the advantages provided by the examples and embodiments described below are illustrative in nature, and not all examples and embodiments provide the same advantages or the same degree of advantages.

The specific implementation mode comprises the following parts in sequence: (1) defining; (2) to summarize; (3) examples, components, and alternatives; (4) illustrative combinations and additional examples; (5) advantages, features and benefits; and (6) a conclusion. Examples, components, and alternatives are further divided into sections a through F, each section labeled accordingly.

Definition of

The following definitions apply herein unless otherwise indicated.

"substantially" means more or less conforming to a particular size, range, shape, concept, or other aspect modified by the term such that the features or components do not need to be precisely conformed. For example, an object that is "substantially cylindrical" means that the object resembles a cylinder, but may have one or more deviations from a true cylinder.

"comprising," "including," and "having" (and variants thereof) are used interchangeably to mean including, but not necessarily limited to, and are open-ended terms that are not intended to exclude additional, unrecited elements or method steps.

terms such as "first," "second," and "third" are used to distinguish or identify various members of a group, etc., and are not intended to represent sequential or numerical limitations.

SUMMARY

Generally, a matched compression mold apparatus according to the present teachings includes a first compression mold part and a second compression mold part. A workpiece (also referred to as a charge) is disposed between respective intermediate portions of the first and second mold parts. The intermediate portion is configured to form the workpiece into a desired shape. The matched compression mold apparatus further includes a compression device configured to compress the intermediate portions toward one another. The heating mechanism of the compression mold apparatus heats the intermediate portion to facilitate forming and/or curing of the workpiece.

One or more components of a mating compression mold apparatus may be additively manufactured. Additive manufacturing typically includes: applying a raw material (e.g., metal, thermoplastic, etc.) in an ordered layer according to the digital design information; and selectively bonding and/or fusing the applied layers to produce the desired object. Additive manufacturing techniques may include 3D printing, rapid prototyping, direct digital manufacturing, layered manufacturing, additive manufacturing, and the like. One or both compression mold components of the present disclosure may be produced by additive manufacturing. In some examples, only a middle portion of the compression mold part is produced by additive manufacturing, while other portions of the compression mold part and the apparatus are manufactured by conventional means such as machining.

In some examples, the intermediate portions of the additive manufacturing of the compression mold component are interchangeable. For example, multiple intermediate portions, each configured to shape a workpiece into a different shape, may be additively manufactured and selectively installed in a common frame structure.

The matched compression mold apparatus described herein is typically used to manufacture aircraft interior panels. For example, if the apparatus is to be used to convert a workpiece into a contour panel, the intermediate portions of the compression mold components may each be configured to shape a contour on a side of the workpiece.

Examples, Components and alternatives

The following sections describe selected aspects of exemplary compression mold apparatuses and associated systems and methods. The examples in these sections are intended for illustration and should not be construed as limiting the overall scope of the disclosure. Each section may include one or more different implementations or examples, and/or include contextual or related information, functionality, and/or structure.

A. Illustrative sandwich panel

As shown in fig. 1-2, this section describes an illustrative sandwich panel 25. The sandwich panel 25 is one example of an aircraft interior panel that can be manufactured using a compression mould apparatus as described above.

figure 1 is an isometric view of a sandwich panel 25. One or more sandwich panels 25 may be used to form interior parts of the aircraft, such as floors, ceilings and/or walls. The sandwich panel 25 is a sandwich composite panel comprising a plurality of layers and generally has a contoured shape. The first side 27 and the second side (not shown) of the sandwich panel 25 may have the same profile (as shown in fig. 1) or may have different profiles.

Fig. 2 depicts illustrative layers of a sandwich panel 25. The sandwich panel 25 comprises a honeycomb core 32 arranged between a first facing 33 and a second facing 34. Facings 33 and 34 may each include a thermoset polymer matrix, such as an epoxy resin and/or a phenolic resin, and may also contain a reinforcement system, such as carbon fiber, aramid, glass fiber, woven glass fiber cloth, and the like. Additionally or alternatively, facings 33 and 34 may include thermoplastic materials and/or other polymers.

honeycomb core 32 includes a plurality of hollow columns 36 arranged in a honeycomb pattern, each column having a substantially hexagonal cross-section and extending between facings 33 and 34. Adhesive film layers 38 and 39 may be included to bond the respective sides of the honeycomb core to the facings 33 and 34. In some examples, the sandwich panel 25 further comprises one or more flame retardant coatings 40. Additionally or alternatively, the coating 40 may include decorative materials, such as paint.

The sandwich panel 25 is one example of an object that can be manufactured using a compression mould apparatus as described above. For example, the sandwich panel 25 may be manufactured using a compression mould apparatus during the crush core forming process. Additionally or alternatively, the compression mold apparatus may be used to manufacture other types of panels and/or other types of objects.

B. illustrative matched compression mold apparatus

As shown in fig. 3-13, this section describes an illustrative mating compression mold apparatus 50. The matched compression mold apparatus 50 is one example of a matched compression mold apparatus as described above. As schematically shown in fig. 3, the matched compression mold apparatus 50 includes a first mold part 55 for additive manufacturing, a second mold part 56 for additive manufacturing, a compression device 57, and a heating mechanism 58.

Fig. 4 depicts a matched compression mold apparatus 50 comprising an additive manufactured first mold part 55 and an additive manufactured second mold part 56. The first mould part 55 of the additive manufacturing comprises a first intermediate portion 61 supported by a first frame structure 63. The second mould part 56 of the additive manufacturing comprises a second intermediate portion 66 supported by a second frame structure 68. In typical use, first additive-manufactured mold part 55 is arranged above second additive-manufactured mold part 56, with first intermediate portion 61 and second intermediate portion 66 facing each other.

The first and second intermediate portions 61, 66 are configured to cooperatively form opposing sides of a workpiece 70 (see fig. 5) disposed therebetween. For example, first intermediate portion 61 may be configured to form a contour on a first side (not shown) of workpiece 70, and second intermediate portion 66 may be configured to form a contour on a second side 72 of workpiece 70. Fig. 5 is a partially exploded view of the compression mold apparatus 50 illustrating the position of the workpiece 70 between the first intermediate portion 61 and the second intermediate portion 66.

Generally, the compression mold apparatus 50 is configured to manufacture interior panels of aircraft, such as solid thermosetting phenolic wallboard, sandwich thermosetting phenolic wallboard, and the like. Thus, in some examples, the first and second intermediate portions 61, 66 include substantially flat and/or contoured first and second forming surfaces 73, 76, respectively (see fig. 11), the first and second forming surfaces 73, 76 being configured to form the workpiece 70 into a plate. In some examples, the first forming surface 73 of the first intermediate portion 61 is convex in profile and the second forming surface 76 of the second intermediate portion 66 is concave in profile. In these examples, the first intermediate portion 61 may be referred to as a core member, and the second intermediate portion 66 may be referred to as a cavity member. In the drawings of the present disclosure, the bottom mold part is depicted as including a core component and the top mold part is depicted as including a cavity component. However, in some examples, the bottom mold part comprises a cavity member and the top mold part comprises a core member.

In some examples, first intermediate portion 61 and second intermediate portion 66 have similar curvatures, geometric features, and/or material compositions. These examples may be suitable for forming aircraft panels having a substantially uniform thickness with matching offset curvatures on both sides of the aircraft panel.

In some examples, the first and second intermediate portions 61, 66 are configured to be interchangeable, and the first and second frame structures 63, 68 are universal and/or fixed structures configured to selectively support any of a plurality of different interchangeable intermediate portions. A plurality of different interchangeable first intermediate portions 61 and/or a plurality of different interchangeable second intermediate portions 66 may be provided for forming differently shaped workpieces 70. For example, an aircraft panel having a particular shape may be manufactured using a selected first intermediate portion 61 and a selected second intermediate portion 66 configured to mold the particular panel shape.

Fig. 6-10 depict an illustrative first intermediate portion 61. Fig. 6 is an isometric view of the intermediate portion 61 depicting the convex shaping surface 73. Fig. 7 and 8 are a top view and a front view, respectively, of the intermediate portion 61. Fig. 9 is a sectional view taken in the direction shown in fig. 7, and fig. 10 is a sectional view taken in the direction shown in fig. 8.

Fig. 11 and 12 are exploded views depicting first and second additive-manufactured mold components 55, 56, including first and second intermediate portions 61, 66 mounted to first and second frame structures 63, 68, respectively. In the example depicted in fig. 11 and 12, the first and second intermediate portions 61 and 66 are attached to the first and second frame structures 63 and 68, respectively, using a bolt and pin assembly. Additionally or alternatively, the first and second intermediate portions 61, 66 may be attached to the first and second frame structures 63, 68 using latches, clips, clamps, screws, nails, and/or any other suitable fasteners. In some examples, first and second frame structures 63, 68 include grooves, slots, and/or other suitable openings configured to receive portions of first and second intermediate portions 61, 66, and the intermediate portions are mounted within the respective frame structures by positioning the intermediate portions such that the portions are received within the respective openings.

As described above, the first intermediate portion 61 and the second intermediate portion 66 may be configured to be interchangeable, and the first frame structure 63 and the second frame structure 68 may be fixed. Thus, the mechanism for mounting the first and second intermediate portions 61, 66 to the first and second frame structures 63, 68 may be configured such that the intermediate portions may be easily mounted to and removed from the respective frame structures without damaging the intermediate portions or the frame structures. The bolt and pin assembly depicted in fig. 11-12 is an example of a mounting mechanism that is capable of mounting and removing interchangeable first and second intermediate portions 61, 66 to and from first and second frame structures 63, 68.

as mentioned above, the first intermediate portion 61 and the second intermediate portion 66 are typically at least partially manufactured by additive manufacturing. For example, first intermediate portion 61 and second intermediate portion 66 may be additively manufactured, for example, from a metal and/or thermoplastic material. The relatively small cost and manufacturing time required to additively manufacture first and second intermediate portions 61, 66 may facilitate production of different first and second intermediate portions configured to manufacture, for example, different aircraft panel structures. The first frame structure 63 and the second frame structure 68 may be wholly or partially additive manufactured and/or may be manufactured by other means (e.g., machining). The first frame structure 63 and the second frame structure 68 are generally rigid structures.

The first frame structure 63 and the second frame structure 68 may include alignment features configured to facilitate proper alignment of the frame structures when the frame structures are pressed together to shape the workpiece 70. As depicted in fig. 11-12, the first frame structure 63 may include one or more alignment protrusions 79 protruding from the first frame structure, and the second frame structure 68 may include corresponding alignment notches 82 configured to receive the alignment protrusions. Optionally, one or more alignment blocks 85 (e.g., spacer blocks and/or spacer blocks) may be disposed on the alignment protrusions 79 and/or within the alignment notches 82 to adjust the alignment and/or vertical spacing between the first and second frame structures 63, 68.

As shown in fig. 11-12, a first heater blanket 87 is attached to first intermediate portion 61, and a second heater blanket 90 is attached to second intermediate portion 66. First heater blanket 87 and second heater blanket 90 are examples of heating mechanisms 58 for mating compression mold apparatus 50, as described above. Generally, first heating blanket 87 is attached to a first non-forming surface 93 (see fig. 8-10) of first intermediate portion 61 opposite first forming surface 73, and second heating blanket 90 is attached to a second non-forming surface 96 (see fig. 5) of second intermediate portion 66 opposite second forming surface 76. First and second heat blankets 87, 90 are configured to provide heat to first and second mold sections 55, 56, which may facilitate molding of workpiece 70 (e.g., molding of thermoplastic and/or other polymeric materials in the workpiece. additionally or alternatively, the heat provided by first and second heat blankets 87, 90 may facilitate curing of any thermoset materials within the workpiece.

in some examples, first and second heat blankets 87, 90 include "smart susceptors" configured to maintain temperatures within a predetermined range using automatic variation in the amount of heat generated by induction heating based on the difference between the actual temperature and the curie temperature of the susceptors. Additionally or alternatively, first heater blanket 87 and second heater blanket 90 may be configured to generate heat through resistive heating. In some examples, first and second heating blankets 87, 90 comprise carbon nanotube films configured to generate heat by, for example, resistive heating.

In some examples, first and second heating blankets 87, 90 comprise a plurality of heating blankets disposed adjacent to one another on first and second non-forming surfaces 93, 96, respectively. In these examples, first heating blanket 87 and second heating blanket 90 may be referred to as multi-zone heating blankets and/or multi-zone heating blanket systems. Each or a subset of the constituent heater blankets may include a respective power source and processing logic configured to control heat generation. The use of multiple heating blankets may improve thermal uniformity and/or ease with which the heating blankets may be installed and/or replaced.

First and second heater blankets 87, 90 may be bonded to first and second intermediate portions 61, 66 (e.g., to first and second non-forming surfaces 93, 96) by an adhesive. The adhesive may include a resin such as a phenolic resin, an epoxy resin, or the like. In some examples, a material having a high thermal conductivity is incorporated into the adhesive resin to improve the efficiency of heat transfer from first and second heating blankets 87, 90 to first and second intermediate portions 61, 66.

As depicted in fig. 4-5 and 11-12, first and second frame structures 63, 68 may be open substantially adjacent first and second non-forming surfaces 93, 96 to facilitate access to first and second heater blankets 87, 90, e.g., for installation and/or maintenance of the heater blankets. When access to the first and second heating blankets 87, 90 is not desired, removable covers may be provided to cover the openings on the first and second frame structures 63, 68; the cover may prevent damage and/or heat loss.

In some examples, first heater blanket 87 and second heater blanket 90 are omitted and compression mold apparatus 50 is disposed within an oven. In some examples, the oven may be configured to heat the compression mold apparatus 50 by an alternative heating source.

the first and second heat blankets 87, 90 and/or any other heating mechanism 58 may be configured to heat the workpiece 70 to a temperature between 150 and 350 degrees fahrenheit, and/or a temperature between 200 and 300 degrees fahrenheit. In some examples, the heating mechanism 58 is configured to heat the first mold part 55 and the second mold part 56 such that the temperature on each of the first forming surface 73 and the second forming surface 76 is uniform within a predetermined range (e.g., uniform within a tolerance of ± 16 degrees fahrenheit, and/or ± 12 degrees fahrenheit, and/or ± 8 degrees fahrenheit, and/or ± 4 degrees fahrenheit, and/or any other suitable tolerance). If the first and second mold parts 55, 56 are made of thermoplastic material, the mold parts are heated to a temperature (e.g., a temperature suitable for thermosetting the workpiece 70) below the thermoplastic transition temperature. The thermoplastic material remains solid at a temperature above the temperature of the workpiece 70.

Fig. 13 depicts an illustrative press 100 configured to apply a force directing the first and second intermediate portions 61, 66 (e.g., core and cavity members) toward one another. The press 100 is an example of the above-described compression device 57. The press 100 includes a first platen 103, a second platen 106, and an actuator 110, the actuator 110 being configured to force the platens toward each other. The actuator 110 may include one or more hydraulic cylinders, pneumatic cylinders, or the like. The first and second mold parts 55, 56 are positioned between the first and second platens 103, 106 such that pressing the platens toward each other also presses the first and second intermediate portions 61, 66 toward each other. For example, the first platen 103 may engage a bottom side of the first mold part 55 and the second platen 106 may engage a top side of the second mold part 56. In the illustrative press 100, the first platen 103 is fixed in position and the second platen 106 is slidably mounted on a frame 115. An actuator 110, at least partially supported by a frame 115, is configured to urge the second platen 106 toward the first platen 103. The actuator 110 may also be configured to lift the second platen 106 off of the first platen 103. In some examples, instead, the second platen 106 is fixed in position, while the first platen 103 is movable; in other examples, both platens are movable.

the press 100 may be configured to apply a pressure of at least 50 pounds Per Square Inch (PSI) to force the first and second intermediate portions 61, 66 toward one another. In some examples, the press 100 may be configured to apply a pressure of 50PSI to 250PSI, forcing the first and second intermediate portions 61, 66 toward one another.

as described above, at least some of the components of the mating compression mold apparatus 50 are additive manufactured. In some examples, first mold part 55 and second mold part 56 are entirely additive manufactured; in some examples, the first and second intermediate portions 61, 66 are additive manufactured, and the first and second frame structures 63, 68 are manufactured by other methods. Because the mating compression mold apparatus 50 is at least partially additive manufactured, it may have a relatively small weight compared to compression mold apparatuses manufactured by conventional methods. For example, the additive manufacturing portion of the mating compression mold apparatus 50 may be made of a lightweight material (such as a thermoplastic). Additionally or alternatively, the additive manufacturing process may allow for the portions of the mating compression mold apparatus 50 to be manufactured using less material than is feasible with conventional manufacturing methods; thus, the mating compression mold apparatus 50 may be lighter in weight than an apparatus manufactured entirely by conventional methods, even if the additive manufactured portions of the mating compression mold apparatus 50 are made of conventional materials such as steel. In some examples, the mating compression mold apparatus 50 weighs less than 1000 pounds. In some examples, the mating compression mold apparatus 50 weighs less than 500 pounds. In contrast, known matched compression mold apparatuses typically weigh in excess of 10,000 pounds, and may weigh in excess of 14,000 pounds, or in excess of 20,000 pounds.

C. Illustrative method of additive manufacturing

This section describes steps of an illustrative method for additive manufacturing a workpiece (e.g., first and second mold parts 55, 56 and/or first and second intermediate portions 61, 66) for additive manufacturing; see fig. 14. Aspects of the illustrative additive manufacturing device depicted in fig. 15 may be used in the method steps described below. Where appropriate, reference may be made to components and systems that may be used to perform each step. These references are for illustration only and are not intended to limit the possible ways of performing any particular step of the method.

Additive manufacturing is rapidly gaining popularity in many industries as a means of rapid production at relatively low cost. Additive manufacturing may be used to create solid objects from 3D models by building the objects step by step. Additive manufacturing techniques typically apply raw materials in layers and selectively combine the raw materials to produce a desired object. The thickness of each layer may depend on the particular additive manufacturing technique used. Illustrative techniques include Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), Selective Laser Sintering (SLS), fuse fabrication (FFF), wire fed additive manufacturing, and Electron Beam Melting (EBM), among others. Wire-fed additive manufacturing techniques may include Wire and Laser Additive Manufacturing (WLAM), electron beam free form manufacturing (EBF3), Wire and Arc Additive Manufacturing (WAAM), and the like.

Fig. 14 is a flow chart illustrating steps performed in the illustrative method 200, and may not describe a complete process or all of the steps of the method. Although the various steps of method 200 are described below and depicted in fig. 14, the various steps do not necessarily all have to be performed, and in some cases may be performed simultaneously or in a different order than shown.

At step 202, digital information describing an ordered plurality of layers is received. The digital information may be received by a computer controller 312 of an additive manufacturing device 310 as depicted in fig. 15. Additive manufacturing device 310 may also be referred to as a printer or a manufacturer. Computer controller 312 may include any data processing system configured to receive digital design information and control functions for printer 310. The illustrative computer controller shown in FIG. 15 includes a processor 314 for controlling printer functions and a memory 316 for storing received data.

The received information may include geometric data and/or design details for a plurality of two-dimensional patterns of layers that make up a three-dimensional object, where the three-dimensional object is an additive manufactured workpiece 328 to be manufactured. These layers may also be described as cross-sections or slices. The layers are ordered so that they may be numbered or organized from the first layer to the last layer.

Step 204 of method 200 includes depositing the feedstock on a build platform 318 located in a build environment 320 of a printer 310. Build platform 318 may include a support that is movable along a manufacturing axis 322 by computer controller 312. The build platform 318 may have a flat surface perpendicular to the fabrication axis 322.

The feedstock may be any material suitable for additive manufacturing, typically a fluid, powder, and/or wire, and includes, but is not limited to, photopolymer resins, thermoplastics, thermosets, neat and/or reinforced polymeric materials, gypsum, ceramics, and metals. The material may be dispensed from a source 324 of raw material such as a hopper, tank, wire or powder bed. For example, aluminum powder may be swept from the powder bed onto the build platform 318 by a brush arm actuated by the computer controller 312.

The feedstock may be uniformly distributed on build platform 318, or may be deposited in a selected pattern. The deposition may be accomplished under the control of a computer controller 312. In some examples, build platform 318 may be submerged in feedstock, and deposition may be accomplished by gravity or fluid pressure. In some examples, a print head 326 coupled to the source of feedstock 324 may deposit the feedstock in a pattern corresponding to a first layer of the ordered plurality of layers.

At step 206, the feedstock is modified to produce a first layer. In other words, a physical change in the deposited material is caused to implement the first layer as a physical object on build platform 318 in accordance with design information describing the first layer of the ordered plurality of layers and as directed by computer controller 312.

The material may be acted upon by a print head 326 of the printer 310, the print head 326 being controlled by the computer controller 312. For example, the print head 326 may include a laser that cures photopolymer by exposure to light or sinters metal powder by exposure to heat. The print head 326 may be directed by the computer controller 312 to follow a path defined in the received digital information of the first layer and/or a path calculated by the processor 314 based on the received digital information.

step 208 includes repositioning build platform 318. In some examples, build platform 318 may initially be positioned at a selected distance from print head 326. The selected distance may be determined based on the process to be performed by the print head 326. After the layer is produced, build platform 318 may be repositioned along fabrication axis 322 by computer controller 312 away from print head 326 by an amount approximately equal to the layer thickness. That is, build platform 318 may be moved such that the top surface of the resulting layer is separated from print head 326 by a selected distance.

In some examples, build platform 318 may begin to align with another element of printer 310 (such as a material dispensing component). After the layer is produced, build platform 318 may be repositioned by computer controller 312 along manufacturing axis 322 such that the top surface of the produced layer is aligned with the other element of printer 310. In some examples, at step 208, the print head 326 may be repositioned instead of or in addition to the build platform 318 being repositioned. In some examples, step 208 may be skipped.

At step 210, a feedstock is deposited on the layer produced in the previous step of the method 200. The feedstock may be any suitable material and may be deposited in any suitable manner, as depicted in step 204. At step 212, the feedstock is modified to produce the next layer, as previously described with respect to step 206.

Steps 208 through 212 may be repeated to generate each of the plurality of layers of received digital information until the last layer is generated. The resulting first through last layers may then include an additively manufactured workpiece 328 as described in the received digital information. The additively manufactured workpiece may be removed from the printer and post-processed as required. For example, an additive manufactured workpiece may be machined from a build plate of a build platform, and details and/or a smooth surface may be further finished by machining and/or other methods.

D. Illustrative method of making a matched compression molding die

This section describes the steps of an illustrative method 400 of making a matched compression molding die; see fig. 16. Aspects of the illustrative additive manufacturing apparatus 310 and/or method 200 may be used in the method steps described below. Where appropriate, reference may be made to components and systems that may be used to perform each step. These references are for illustration only and are not intended to limit the possible ways of performing any particular step of the method.

Fig. 16 is a flow chart illustrating steps performed in the illustrative method 400, and may not describe a complete process or all of the steps of the method. Although the various steps of method 400 are described below and depicted in fig. 16, the various steps do not necessarily all have to be performed, and in some cases may be performed simultaneously or in a different order than shown.

At step 402, the method 400 includes additive manufacturing a core member. The core member may include, for example, first intermediate portion 61 of illustrative first mold component 55.

at step 404, the method 400 includes additive manufacturing a cavity member. The cavity member may include, for example, a second intermediate portion 66 of the illustrative second mold component 56.

Additive manufacturing steps 402 and 404 may include aspects of additive manufacturing method 200. In some examples, the core member and the cavity member are made of metal. In some examples, the core member and the cavity member are made of a thermoplastic material such as acrylic, nylon, polycarbonate, and the like. Additionally or alternatively, the core member and the cavity member may be made of a thermosetting material and/or a pure polymer material and/or a reinforced polymer material. Steps 402 and 404 may be performed using any suitable additive manufacturing technique.

At step 406, the method 400 includes connecting a first heating element to the core member. The first heating element may include a first heater blanket 87 and/or any other suitable heating mechanism. The step of connecting the first heating element to the core member may comprise disposing the first heating element on a surface of and/or within the core member. In some examples, the step of attaching the first heating element to the core member includes bonding the heating element to a surface of the core member (e.g., the first non-forming surface 93).

At step 408, the method 400 includes connecting a second heating element to the cavity member. The second heating element may include a second heater blanket 90 and/or any other suitable heating mechanism. The step of attaching the second heating element to the cavity member may comprise disposing the second heating element on a surface of the cavity member and/or within the cavity member. In some examples, the step of attaching the second heating element to the cavity member includes bonding the heating element to a surface of the cavity member (e.g., the second non-forming surface 96).

At step 410, the method 400 includes installing the core member and the cavity member in a frame structure configured for shaping a workpiece (e.g., workpiece 70). The frame structure may comprise a first frame structure 63 and a second frame structure 68, and/or any other structure suitable for supporting the core member and the cavity member such that they may be pressed together by the compression means. In some examples, the frame structure is a universal frame structure configured to support different core and cavity members. Different core and cavity members may be configured for use in manufacturing different workpieces, such as aircraft panels of different shapes. In these examples, step 410 includes interchanging different core and/or cavity members in the frame structure to produce different panel structures.

E. Illustrative method of making compression molded parts

This section describes the steps of an illustrative method 500 of manufacturing a compression molded part; see fig. 17. Aspects of illustrative additive manufacturing device 310 may be used in the method steps described below. Where appropriate, reference may be made to components and systems that may be used to perform each step. These references are for illustration only and are not intended to limit the possible ways of performing any particular step of the method.

fig. 17 is a flow diagram illustrating steps performed in the illustrative method 500, and may not describe a complete process or all of the steps of the method. Although the various steps of method 500 are described below and depicted in fig. 17, the various steps do not necessarily all have to be performed, and in some cases may be performed simultaneously or in a different order than shown.

At step 502, the method 500 includes determining a first shape of a first compression molded component to be manufactured. For example, the first compression-molded component may be an aircraft interior panel (e.g., a sandwich panel 25), and the first shape may be determined based on aircraft design information.

At step 504, the method 500 includes fabricating a first core member (e.g., a male compression mold intermediate portion, such as first intermediate portion 61) and a first cavity member (e.g., a female compression mold intermediate portion, such as second intermediate portion 66) configured to co-compression form a first workpiece (e.g., workpiece 70) into the first shape determined at step 502. Typically, the first core member and/or the first cavity member is manufactured by additive manufacturing techniques.

At step 506, the method 500 includes installing the first core member and the first cavity member into a frame structure (e.g., a frame structure including the first frame structure 63 and the second frame structure 68). The frame structure supports the first core member and the first cavity member such that they may be used to shape the first workpiece. The frame structure is a universal structure configured to support different core and cavity members.

At step 508, the method 500 includes shaping the first workpiece using the first core member and the first cavity member to produce a first compression molded part having a determined first shape. For example, a compression device such as the press 100 may be used to press the first cavity member toward the first core member with the first workpiece therebetween such that the first workpiece is formed into a first compression molded part. Shaping the first workpiece at step 508 generally includes heating the first workpiece using a heating mechanism to facilitate shaping and/or curing of the first workpiece.

At step 510, the method 500 optionally includes discarding the first core member and the first cavity member. Because the replacement of the first core member and the first cavity member may be quickly additive manufactured at a relatively low cost, it may be more cost effective to discard the first core member and the first cavity member after use (and/or after a short period of no longer use) rather than storing them until needed again. Discarding the first core member and the first cavity member may include recycling the first core member and/or the first cavity member such that the materials from which the core member and/or the cavity member are made may be reused. For example, the first core member and the first cavity member may be melted, and at least a portion of the melted material may be reused as a feedstock for additive manufacturing of another object. The molten material may be stored and/or processed (e.g., converted into a powder, a fluid, a wire, and/or any other suitable form) prior to reuse.

At step 512, the method 500 optionally includes determining a second shape of a second compression molded component to be manufactured. The second compression-molded component may be an aircraft interior panel (e.g., a sandwich panel 25), and the second shape may be determined based on aircraft design information.

At step 514, the method 500 optionally includes fabricating a second core member (e.g., a male compression mold mid-section, such as the first mid-section 61) and a second cavity member (e.g., a female compression mold mid-section, such as the second mid-section 66), the second core member configured to cooperatively compression mold a second workpiece (e.g., the workpiece 70) into the second shape determined at step 512. Typically, the second core member and/or the second cavity member is additive manufactured. The second core member and/or the second cavity member may be partially or entirely made of a material obtained by recycling the first core member and/or the first cavity member.

In some examples, the second shape of the second compression molded component is the same or nearly the same as the first shape of the first compression molded component. Thus, the second core means and the second cavity means may be identical or almost identical to the first core means and the first cavity means. For example, if the first core member and the first cavity member are discarded at step 510, and it is later determined that the first compression molded part needs to be replicated, a second core member and a second cavity member may be additively manufactured (e.g., as needed) as needed to compression mold a second portion having the same shape as the first portion. The second workpiece may comprise the same material and/or the same interlayer material as the first workpiece.

At step 516, the method 500 optionally includes installing a second core member and a second cavity member into the frame structure. Because the frame structure is a universal frame structure, it supports a second core member and a second cavity member that are different from the first core member and the first cavity member, and a second core member and a second cavity member that are substantially identical to the first member.

At step 518, the method optionally includes forming a second workpiece into a second compression molded component using a second core member and a second cavity member. Step 518 generally includes compression molding the second portion using a compression device and a heating mechanism. The compression device and/or heating mechanism used in step 518 may be the same compression device and/or heating mechanism used in step 508.

The method 500 may be one example of lean manufacturing. For example, manufacturing compression mold parts on demand (e.g., when and/or where parts are needed) may reduce and/or eliminate the need to store a large number of different mold parts. Because the mold parts can be manufactured with relatively little lead time, the parts can be manufactured on an order basis (e.g., the parts can be manufactured when the need for the parts becomes apparent, rather than anticipating such a need). Thus, the risk of manufacturing unwanted mould parts is reduced with respect to conventional methods of manufacturing mould parts. The mould parts may also be manufactured at or near the location where they are to be used. For example, the mold parts may be manufactured in the vicinity of a compression device that is difficult or impossible to move to another location. Thus, the method 500 saves time and energy spent transporting the mold parts to the location where they will be used. Reclaiming material from the first core member and the first cavity member to at least partially form the second core member and the second cavity member also reduces wasted material in accordance with principles of lean manufacturing and environmental sustainability.

F. illustrative combinations and additional examples

This section describes additional aspects and features of a matched compression mold apparatus with additively manufactured parts, given without limitation as a series of paragraphs, some or all of which may be designated alphanumerically for clarity and efficiency. Each of these paragraphs may be combined with one or more other paragraphs and/or with the disclosure elsewhere in this application in any suitable manner. Some of the paragraphs below explicitly mention and further limit other paragraphs, providing but not limiting examples of some suitable combinations.

A0, a matched compression mould apparatus, the apparatus comprising: a first additively manufactured die component having a first intermediate portion configured to profile a first side of a workpiece; a second additively-manufactured mold part having a second intermediate portion configured to profile onto a second side of the workpiece; a heating mechanism configured to heat the first and second intermediate portions sufficiently to solidify the workpiece into a desired shape; and a compression device configured to apply a force directing the first and second intermediate portions toward each other.

A1, the device of paragraph A0, wherein the first intermediate portion and the second intermediate portion are comprised of a polymeric material.

A1a, the device of paragraph A1, wherein the polymeric material comprises a neat polymeric material and/or a reinforced polymeric material.

A1b, the device of paragraph A1, wherein the polymeric material includes a thermoplastic or thermoset material, a neat polymeric material, and/or a reinforced polymeric material.

A2, the apparatus of paragraph A0, wherein the first intermediate portion and the second intermediate portion are comprised of a metallic material.

A3, the apparatus of any of paragraphs A0-A2, wherein the heating mechanism comprises: a first heating blanket connected to a bottom side of the first intermediate portion; and a second heating blanket connected to a top side of the second intermediate portion.

A4 the apparatus of any of paragraphs a 0-A3, wherein each mold section has a rigid frame structure configured to support interchangeable intermediate portions to mold differently shaped workpieces.

A5, the apparatus of any of paragraphs A0-A4, wherein the first intermediate portion and the second intermediate portion are configured to form an aircraft interior panel.

A6, the apparatus of any of paragraphs A0-A5, wherein the first and second intermediate sections are configured for crush core molding of a honeycomb core thermoset sandwich composite panel.

A6a, the apparatus of any of paragraphs a 0-a 5, wherein the first and second intermediate portions are configured to shape thermoplastic wallboard.

A7, the apparatus of any of paragraphs A0-A6, wherein the first and second intermediate sections and corresponding heat blankets are configured to heat a workpiece up to a temperature between 200 and 300 degrees Fahrenheit.

A8, the apparatus of any of paragraphs A0-A7, wherein the compression device comprises a press configured to apply a pressure of at least 50psi that forces the intermediate portions toward each other.

A9, the apparatus of any of paragraphs A0 to A8, wherein the apparatus weighs less than 1000 pounds.

A10, the apparatus of any of paragraphs A0 to A8, wherein the apparatus weighs less than 500 pounds.

B0, a matched compression mold apparatus, comprising: a core member; a cavity member, the core member and the cavity member configured to cooperatively form opposing sides of a panel; a first frame structure configured to support the core member; a second frame structure configured to support the cavity member, wherein the frame structure is universal, the core member and the cavity member being selectively mounted in the respective frame structure and configured to form a particular panel shape.

B1 the apparatus of paragraph B0, wherein the core member and the cavity member are manufactured by additive manufacturing.

B2, the apparatus of any of paragraphs B0-B1, wherein the core member and the lumen member are made of a metallic material.

B3, the apparatus of any of paragraphs B0-B1, wherein the core member and the lumen member are made of a polymeric material.

B3a the apparatus of paragraph B3, wherein the polymeric material comprises a pure polymeric material and/or a reinforced polymeric material.

B3B, the device of paragraph B3, wherein the polymeric material comprises a thermoplastic or thermoset material, a neat polymeric material, and/or a reinforced polymeric material.

B4, the apparatus of any of paragraphs B0-B3, further comprising a compression device configured to apply a force directing the core member and the cavity member toward each other.

B5, the apparatus of any of paragraphs B0-B4, further comprising: a first heating blanket connected to a bottom side of the core member; and a second heating blanket connected to a top side of the cavity member.

C0, a method of making a mating compression molding die, the method comprising the steps of: additive manufacturing a core member; additive manufacturing a cavity member; connecting a first heating element to the core member; connecting a second heating element to the cavity member; and installing the core member and cavity member in a frame structure configured to form a workpiece.

c1, the method of paragraph C0, wherein the frame structure is universal, the installing step comprising: different core and cavity members are interchanged in the frame structure to produce different panel structures.

C2, the method of any of paragraphs C0-C1, wherein the core member and the cavity member are made of a metallic material.

C3, the method of any of paragraphs C0 to C1, wherein the core member and cavity member are made of a polymeric material.

c3a, the method of paragraph C3, wherein the polymeric material comprises a neat polymeric material and/or a reinforced polymeric material.

C3b, the method of paragraph C3, wherein the polymeric material comprises a thermoplastic or thermoset material, a neat polymeric material, and/or a reinforced polymeric material.

D0, a method of making a compression-molded part, the method comprising the steps of:

Determining a first shape of a first compression molded part to be manufactured;

Manufacturing a first core member and a first cavity member configured to cooperatively compression mold a first workpiece into the determined first shape;

Installing the first core member and the first cavity member into a frame structure; and

Forming the first workpiece using the first core member and the first cavity member to produce the first compression-formed component having the determined first shape.

D1, the method of paragraph D0, wherein the step of manufacturing the first core member and the first cavity member includes: additive manufacturing the first core member and the first cavity member.

D2, the method of any of paragraphs D0-D1, further comprising the steps of: after the pressing step, discarding the first core member and the first cavity member.

D3, the method of any of paragraphs D0-D2, wherein the first compression-molded component is an aircraft interior panel.

D4, the method of any of paragraphs D0-D3, further comprising the steps of:

determining a second shape of a second compression molded part to be manufactured;

Manufacturing a second core member and a second cavity member configured to cooperatively compression mold a second workpiece into the determined second shape;

Installing the second core member and the second cavity member into the frame structure; and

Forming the second workpiece using the second core member and the second cavity member to produce the second compression-formed component having the determined second shape.

D5, the method of paragraph D4, wherein the step of manufacturing a second core member and a second cavity member includes: additive manufacturing the second core member and the second cavity member.

D6, the method of any of paragraphs D4-D5, wherein the second shape is the same as the first shape.

D7, the method of any of paragraphs D4-D6, wherein the second compression-molded component is an aircraft panel.

Advantages, features and benefits

The different embodiments and examples of mating compression mold apparatus described herein provide several advantages over known solutions for compression molding thermoset aircraft panels and/or other components. For example, the illustrative embodiments and examples described herein allow for the production of compression mold tool components at relatively high speeds and at low cost, as compared to conventional production methods, particularly where the compression mold tool components are configured to compression mold components having complex profiles.

Additionally, the illustrative embodiments and examples described herein allow for the manufacture of compression mold components having interchangeable intermediate portions (e.g., interchangeable cavity and core members) that may be supported by a common frame portion, among other benefits. Thus, the illustrative embodiments and examples described herein allow for relatively quick and easy manufacturing and storage of compression mold tools configured to shape different parts in a relatively small space.

Additionally, the illustrative embodiments and examples described herein allow the compression mold component, or portions thereof, to be considered disposable, among other benefits. Because the additively manufactured mold parts and/or the intermediate portions of the mold parts are relatively fast and inexpensive to manufacture, in some cases the parts (and/or the intermediate portions of the parts) may be manufactured as desired and discarded after use rather than storing them.

Additionally, the illustrative embodiments and examples described herein allow, among other benefits, compression mold components to be cost effectively manufactured, even where the components are intended for compression molding a small number of components. For example, a compression mold component may be manufactured that is configured to compression mold a small number of replacement panels for an aircraft model that is no longer being produced. In contrast, conventional compression mold parts are very expensive and time consuming to manufacture, and thus it is often not feasible to manufacture parts for molding only a small number of parts.

Additionally, the illustrative embodiments and examples described herein allow, among other benefits, the manufacture of compression mold tool components while wasting less material than is typically wasted in subtractive manufacturing techniques.

Additionally, the illustrative embodiments and examples described herein allow for the manufacture of compression mold tool components that are significantly lower in weight than conventional components, among other benefits. Accordingly, the compression mold tool component of the present disclosure may be moved about the manufacturing environment to increase flexibility in manufacturing compression molded components. For example, the exchangeable intermediate part of the compression mould part can easily be moved from the storage space to the compression means and then back into the storage space. The storage space may be a remote storage space remote from the compression device. The compression mold tool components described herein may also be used with compression devices that require less power than conventional tool components, particularly where the compression devices are configured to lift one or more tool components.

No known system or device can perform these functions. However, not all embodiments and examples described herein provide the same advantages or the same degree of advantages.

Conclusion

The disclosure set forth above may encompass a variety of different examples with independent utility. While each of these examples has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. As to the section headings used in this disclosure, these headings are for organizational purposes only. The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and/or properties disclosed herein. The following claims particularly point out certain combinations and subcombinations regarded as novel and nonobvious. Other combinations and subcombinations of features, functions, elements, and/or properties may be claimed in applications claiming priority from this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.