Molding apparatus

Abstract

The present invention relates to a method for manufacturing a thermoplastic compound (41) using a system (1), the system comprising: a molding apparatus (2) including a first thermally conductive flange (21) and a second thermally conductive flange (22) defining a cavity configured to receive a thermoplastic prepreg fabric (4); and a thermally conductive mold conditioned by a heat transfer fluid (23), the thermally conductive mold including an upper cavity (24) and a lower cavity (25), the upper cavity... (24) and the lower cavity (25) are configured to receive the first (21) and the second (22) heat-conducting flanges, and a press (3) comprising an upper pressure plate (31) and a lower pressure plate (32), the upper pressure plate having an upper cavity (24) of a temperature-regulating and heat-conducting mold (23) attached thereto, and the lower pressure plate having a lower cavity (25) of a temperature-regulating and heat-conducting mold attached thereto, the method for manufacturing a thermoplastic composite comprising the steps of: A. providing a thermoplastic prepreg fabric (4) comprising fibers and a thermoplastic matrix. B. Insert the thermoplastic prepreg fabric (4) into the first thermally conductive flange (21) and the second thermally conductive flange (22), C. Transfer the thermally conductive flanges (21, 22) into a press (3) including a thermally conductive mold conditioned by a heat transfer fluid (23), D. Preheat the thermally conductive flanges (21, 22) using the mold in the press, E. Press the thermally conductive flanges (21, 22), F. Transfer the thermally conductive flanges (21, 22) into an infrared (IR) oven, G. Using The thermally conductive flanges (21, 22) are heated by infrared heating to melt the thermoplastic matrix; H. the thermally conductive flanges (21, 22) are transferred to a press (3) including a thermally conductive mold conditioned by a heat transfer fluid (23); I. the thermally conductive flanges (21, 22) in the press (3) are cooled; J. the thermally conductive flanges (21, 22) in the press (3) are pressed; K. the thermally conductive flanges (21, 22) are extracted from the press (3); and L. the thermoplastic composite is removed from the mold (41).

Description

Technical Field

[0001] The present invention relates to a molding apparatus, a system for manufacturing thermoplastic composites, and a method for manufacturing thermoplastic composites. Background Technology

[0002] Current methods for manufacturing thermoplastic composites from thermoplastic prepreg fabrics are based on the principle of hot compression. Hot compression involves applying pressure to the thermoplastic prepreg fabric at high temperatures. However, a disadvantage of the hot compression method is its low productivity, particularly due to the long cycle time. In fact, the rate of temperature rise and fall in this method is very slow.

[0003] Heating thermoplastic prepreg fabrics using tools is known. Different heating techniques can be used, including conductive heating, convection heating, or radiant heating. Conductive heating includes ceramic heating and resistance heating. This type of heating is particularly useful for heating the press plates of presses. Convection heating can be carried out using heat transfer fluids. Radiant heating can be achieved through infrared radiation, microwaves, or induction.

[0004] In recent decades, various manufacturing methods for thermoplastic composites have been developed, such as thermoplastic injection molding or stamping.

[0005] Typically, the first step involves creating a sheet or laminate by reinforcing a fabric impregnated with a thermoplastic matrix or resin. In other words, once the thermoplastic matrix or resin has penetrated to the center of the fabric, a sheet or laminate is formed. Stamping methods involve shaping the sheet or laminate in a press under high pressure and temperature, followed by cooling to obtain a crystalline structure that is suitable and decisive for the mechanical properties of parts made from the composite. However, stamping is expensive and energy-intensive. Furthermore, demolding of the composite occurs at high temperatures, posing a risk of burns to the user, and cooling is done outside the tooling, making it difficult to control and repeat.

[0006] Document EP2349667 discloses a molding apparatus for converting materials, comprising:

[0007] The lower mold body or cavity is made of conductive material and includes a molding area for contact with the material to be converted;

[0008] The upper mold body or punch is made of a conductive material and includes a molding area designed to contact the material to be transformed.

[0009] A removable intermediate component or core, made of conductive material, is placed between the die and the punch;

[0010] The sensing device generates a magnetic field that surrounds the die, punch, and intermediate component. These three components are electrically insulated in pairs, such that the opposing surfaces of the intermediate component and the die, and the opposing surfaces of the intermediate component and the punch, define two gaps in which the magnetic field flows. This magnetic field induces current on the surfaces of the molding area, the die, and the punch, thereby enabling the inductor to act on the surface of the molding area.

[0011] The induction heating method disclosed in document EP2349667 is energy-intensive and complex to implement. Furthermore, the structure of the molding apparatus, especially the intermediate components, does not allow for control over the dimensions of the material to be converted, the reduction of temperature cycles, or the generation of inhomogeneities in the material. In fact, heat diffusion within the molding apparatus is non-uniform. Therefore, the quality of the thermoplastic composite may vary. Finally, only thin parts made of thermoplastic composites can be manufactured. Summary of the Invention

[0012] This invention aims to remedy the aforementioned drawbacks by providing a molding apparatus, a system for manufacturing pre-finished parts made of thermoplastic composites, and a method for manufacturing pre-finished parts made of thermoplastic composites, thereby facilitating the shaping of thermoplastic prepreg fabrics. Furthermore, this invention aims to provide a molding apparatus and a system for manufacturing pre-finished parts made of thermoplastic composites that enable optimization of the energy efficiency of the method for manufacturing pre-finished parts made of thermoplastic composites. Finally, this invention aims to provide a molding apparatus, a system for manufacturing pre-finished parts made of thermoplastic composites, and a method for manufacturing pre-finished parts made of thermoplastic composites to ensure control over the dimensions of the parts made of thermoplastic composites, thereby allowing for accelerated preheating and temperature homogenization of the thermoplastic prepreg fabric, while maintaining the high quality of the thermoplastic composite and limiting waste generation.

[0013] The subject of this invention is a molding apparatus comprising:

[0014] A first thermally conductive flange and a second thermally conductive flange define a cavity configured to receive a thermoplastic prepreg fabric.

[0015] A mold, which is temperature-controlled and heat-conducted by a heat transfer fluid, and includes an upper mold and a lower mold, the upper mold and the lower mold being configured to receive a first heat-conducting flange and a second heat-conducting flange.

[0016] The molding apparatus according to the invention facilitates the molding of thermoplastic prepreg fabrics. In fact, the stacking of the thermoplastic prepreg fabrics takes place within a cavity defined by first and second lightweight thermally conductive flanges, the thermal conductivity of which is optimized. Furthermore, the energy efficiency of the method for manufacturing thermoplastic composites is improved. Indeed, the molding apparatus reduces the energy required for its operation due to the combination of the first and second thermally conductive flanges with a temperature-controlled and thermally conductive mold, and also due to the fact that the mold is temperature-controlled and thermally conductive. The mold is temperature-controlled, unlike prior art devices (where presses are typically temperature-controlled). This has the effect of concentrating heat around the first and second thermally conductive flanges more quickly and efficiently, while avoiding heating thick press plates that only partially diffuse heat. The temperature-controlled mold has the effect of ensuring the recrystallization of the thermoplastic composite. Furthermore, the fact that the temperature-controlled and thermally conductive mold and the thermally conductive flanges, independent of the press, are removable, has the advantage of better consolidation of the thermoplastic prepreg fabric, while also benefiting the method for manufacturing thermoplastic composites. The method for manufacturing the thermoplastic compound can then be implemented on an industrial scale, particularly continuously. Furthermore, the first and second thermally conductive flanges, as well as the temperature-regulating and thermally conductive mold, have compatible thermal expansion to ensure control over the dimensions of the thermoplastic compound.

[0017] In one embodiment, the first and second thermally conductive flanges have a strength greater than 30 W·m. -1 ·K -1 The mold, which has a thermal conductivity greater than 30 W·m⁻¹, and is conditioned and heated by a heat transfer fluid, has a thermal conductivity greater than 30 W·m⁻¹. -1 ·K -1 The thermal conductivity is [value missing]. Preferably, the first and second thermally conductive flanges have a thermal conductivity greater than 49 or greater than 55 W·m. -1 ·K -1 The thermal conductivity is high. In this embodiment, the first and second thermally conductive flanges and the thermally conductive and temperature-regulating mold ensure optimized heat transfer and maintain temperature uniformity within them, while preserving the best quality of the thermoplastic composite.

[0018] In one embodiment, the first and second thermally conductive flanges are made of steel, aluminum, or a thermosetting composite material coated with a black oxide. For example, the first and second thermally conductive flanges are made of a composite comprising long carbon fibers and a thermoplastic matrix made of BMI, or of a composite comprising diced carbon fibers and, for example, a thermoplastic matrix made of BMI. The composite is made of a thermoplastic matrix derived from BMI. Preferably, the first and second thermally conductive flanges are made of steel coated with black oxide. In this embodiment, the thermal conductivity of the first and second thermally conductive flanges is optimized.

[0019] In one embodiment, the thickness of the first and second thermally conductive flanges is between 1 and 15 mm. Preferably, the thickness of the first and second thermally conductive flanges is between 1 and 10 mm, and advantageously between 1 and 5 mm. In this embodiment, heat transfer is improved due to the lower thickness of the thermally conductive flanges.

[0020] In one embodiment, the first and second thermally conductive flanges include removable assembly devices. For example, the removable assembly device is a locking screw. In this embodiment, the assembly of the first and second thermally conductive flanges ensures the maintenance and performance of the thermoplastic prepreg fabric.

[0021] In one embodiment, the assembly device defines a gap between the first and second thermally conductive flanges. In this embodiment, a thermoplastic prepreg fabric occupies the cavity defined by the thermally conductive flanges, thus obtaining a part made of a thermoplastic composite with the desired dimensions without cutting. This arrangement ensures complete filling of the cavity defined by the two flanges, as the gap is cleared during the pressing step.

[0022] In one embodiment, the temperature-regulating mold is made of steel.

[0023] In one embodiment, the heat transfer fluid is selected from water or oil.

[0024] The subject of this invention is also a system for manufacturing thermoplastic composites, comprising:

[0025] The molding apparatus according to the present invention, and

[0026] A press comprising an upper pressure plate for a cavity containing an inherently temperature-regulating and heat-conducting mold and a lower pressure plate for a cavity containing an inherently temperature-regulating and heat-conducting mold.

[0027] The system for manufacturing thermoplastic composites according to the present invention enables improved energy efficiency of methods for manufacturing thermoplastic composites while ensuring high quality of the thermoplastic composites. In fact, the heating of the thermally conductive flange is carried out through a temperature-controlled and heat-conducting mold, which allows energy loss to be avoided and optimizes heat diffusion within the thermally conductive flange.

[0028] Finally, the subject of this invention is a method for manufacturing thermoplastic compounds using a system for manufacturing thermoplastic compounds according to the invention, the method comprising the following steps:

[0029] A. Provides thermoplastic prepreg fabrics comprising fibers and a thermoplastic matrix.

[0030] B. Insert the thermoplastic prepreg fabric into the first and second thermally conductive flanges.

[0031] C. Transfer the heat-conducting flange to a press comprising a mold that is temperature-controlled and heat-conducted by a heat transfer fluid.

[0032] D. The heat-conducting flange is preheated using a mold in the press.

[0033] E. Press down the thermally conductive flange.

[0034] F. Transfer the heat-conducting flask to the infrared oven.

[0035] G. Heating the thermally conductive flange under infrared light to melt the thermoplastic matrix.

[0036] H. Transfer the thermally conductive flange to a press comprising a mold that is temperature-controlled and thermally conductive by a heat transfer fluid.

[0037] I. Cooling the heat-conducting flange in the press.

[0038] J. Press the heat-conducting flange in the press.

[0039] K. The heat-conducting flange is extracted from the press, and

[0040] L. Demold the thermoplastic composite.

[0041] The method according to the invention improves energy efficiency while reducing manufacturing cycle time for thermoplastic composites. This, in turn, increases the productivity of the method. In fact, the molding equipment and system used to manufacture thermoplastic composites enable optimized heating and cooling cycles. During preheating in step D), a thermally conductive flange and a temperature-regulating and thermally conductive mold cooperate to increase and homogenize heat diffusion. During heating in step G), the thermally conductive flange is heated under infrared light to promote the melting of the thermoplastic matrix of the thermoplastic prepreg fabric. The molding equipment can control expansion phenomena and also optimize cooling in step I), thereby optimizing the crystallization of the thermoplastic matrix of the thermoplastic composite. During step L), demolding is performed at a temperature that allows the part to be manipulated without posing a risk of burns to the user. Furthermore, the method yields ready-to-use, near-finished parts made from the thermoplastic composite, requiring little or no cutting. In fact, the thermally conductive flange is pre-sized to obtain the desired part made from the thermoplastic composite. Moreover, the press used in this method is a conventional press, which allows for reduced production costs. Furthermore, various thermoplastic composites can be produced quickly and efficiently. In fact, the thermally conductive flange can be easily varied in thickness, shape, and pattern. The method according to the invention ensures reproducibility of parts, low cost, and enables optimized molding of near-finished parts.

[0042] For example, in step A), the thermoplastic prepreg fabric comprises fibers selected from: short or continuous fibers, natural fibers, organic fibers, or mineral fibers. For example, the fibers are selected from: basalt fibers, carbon fibers, and glass fibers. For example, in step A), the thermoplastic matrix is ​​composed of polyolefins, polycarbonates, polyamides, polystyrene, polyesters, and / or polyaryletherketones. For example, a thermoplastic matrix made of polyphenylene sulfide, a thermoplastic matrix made of polyethylene, or a thermoplastic matrix made of polyethylene terephthalate.

[0043] In one embodiment, in step D), the mold is preheated by convection or conduction. Conductive heating includes ceramic heating and resistance heating. Convection heating can be performed using a heat transfer fluid. In this embodiment, heat diffusion is improved.

[0044] In one embodiment, in step D), the preheating of the mold is performed at a temperature between 50°C and 150°C. Unlike prior art where presses are typically heated to approximately 350°C, in this embodiment, the thermally conductive flange and the thermally conductive and temperature-regulating mold are designed to optimize energy efficiency, particularly by significantly reducing the preheating temperature. In fact, the thermally conductive mold is heated to diffuse heat toward the thermally conductive flange, which has the effect of increasing heat transfer without energy loss.

[0045] In one embodiment, in step D), preheating is performed for 1 to 10 minutes. In this embodiment, the heat diffusion of the molding equipment is effective, which has the effect of reducing heating time and thus increasing productivity while optimizing energy efficiency.

[0046] In one embodiment, in steps E) and / or J), pressing is performed on a 10×10 6 Up to 60×10 6 The test is conducted under pressures between Pa.

[0047] In one embodiment, the method includes a step M), performed after step E) or step J), which includes evacuating the first and second thermally conductive flanges. In this embodiment, evacuation improves the penetration of the molten thermoplastic matrix into the fibers. Furthermore, evacuation maintains the orientation of the fibers contained in the thermoplastic prepreg fabric to prevent oxidation of the thermoplastic matrix, remove potential contaminants, and prevent delamination of the thermoplastic prepreg fabric during molding. Finally, the vacuum keeps the thermoplastic matrix fluidized.

[0048] In one embodiment, the seal is inserted between the first and second thermally conductive flanges. For example, the seal is heat-resistant. For example, the compression coefficient of the seal is between 0.1 and 10 mm, preferably between 0.1 and 5 mm, and advantageously between 0.1 and 3 mm.

[0049] In one embodiment, in step G), the first and second thermally conductive flanges are heated at the melting temperature of the thermoplastic matrix of the thermoplastic prepreg fabric.

[0050] In one embodiment, in step G), the heating of the first and second thermally conductive flanges is performed for 5 to 15 minutes. In this embodiment, the preheating step D) and the thermally conductive flanges enable a reduction in heating time.

[0051] In one embodiment, in step I), the first and second thermally conductive flanges are cooled at a temperature at least 10°C lower than the glass transition temperature of the thermoplastic matrix. In this embodiment, the user can manipulate the first and second thermally conductive flanges without any risk of burns.

[0052] In one implementation, in step I), cooling is performed for 1 to 10 minutes.

[0053] In one embodiment, the thermoplastic prepreg fabric includes electronic components based on inorganic or organic compounds. For example, the electronic components are selected from near-field communication tags or radio identification tags. In this embodiment, the user can easily track the thermoplastic compound.

[0054] In one embodiment, a single press is used during steps C) and H). In other words, the same press is used in steps C) and H).

[0055] In one embodiment, two separate presses are used during steps C) and H). In other words, a first press is used in step C) and a second press is used in step H). In this embodiment, the method enables the continuous manufacturing of parts on an industrial scale. Attached Figure Description

[0056] The invention will be better understood from the following description relating to one or more embodiments of the invention, given by way of non-limiting examples and explained with reference to the accompanying schematic diagrams, wherein:

[0057] Figure 1 This is an overview diagram of a system for manufacturing thermoplastic compounds according to the present invention.

[0058] Figure 2 This is a side view of a system for manufacturing thermoplastic composites according to the present invention.

[0059] Figure 3 This is a schematic diagram of a method for manufacturing a thermoplastic compound according to the present invention.

[0060] Figure 4 This is an overview diagram of a part of a method for manufacturing a thermoplastic compound according to the present invention.

[0061] Figure 5 This is an overview diagram of a part of a method for manufacturing a thermoplastic compound according to the present invention.

[0062] Figure 6 This is an overview diagram of a part of a method for manufacturing a thermoplastic compound according to the present invention.

[0063] Figure 7 This is an overview diagram of a part of a method for manufacturing a thermoplastic compound according to the present invention.

[0064] Figure 8 This is an overview diagram of a part of a method for manufacturing a thermoplastic compound according to the present invention.

[0065] Figure 9 This is an overview diagram of a part of a method for manufacturing a thermoplastic compound according to the present invention.

[0066] Figure 10 This is an overview diagram of a part of a method for manufacturing a thermoplastic compound according to the present invention.

[0067] Figure 11 This is an overview diagram of a part of a method for manufacturing a thermoplastic compound according to the present invention.

[0068] Figure 12 This is an overview diagram of a method for manufacturing a thermoplastic compound according to the present invention, and

[0069] Figure 13 This is an overview diagram of a method for manufacturing thermoplastic composites according to the present invention. Detailed Implementation

[0070] Figure 1 and Figure 2 A system 1 for manufacturing thermoplastic compounds is shown, comprising:

[0071] Molding equipment 2 and

[0072] The press 3 includes an upper pressure plate 31 and a lower pressure plate 32.

[0073] The molding apparatus 2 includes a first thermally conductive flange 21 and a second thermally conductive flange 22, which define a cavity configured to receive a thermoplastic pre-impregnated fabric. The thermal conductivity of the first thermally conductive flange 21 and the second thermally conductive flange 22 is greater than 30 W·m. -1 ·K -1 And preferably greater than 49 or greater than 55 W·m -1 ·K -1 .

[0074] The first thermally conductive flange 21 and the second thermally conductive flange 22 are made, for example, of steel, aluminum, or thermosetting composite materials coated with black oxide. Preferably, the first and second thermally conductive flanges are made of steel coated with black oxide, which has the effect of increasing thermal conductivity.

[0075] The molding apparatus 2 further includes a temperature-controlled and heat-conducting mold 23, which includes an upper cavity 24 and a lower cavity 25, and has a temperature greater than 30 W·m. -1 ·K -1 The upper cavity 24 and the lower cavity 25 are configured to receive the first thermally conductive flange 21 and the second thermally conductive flange 22, given the thermal conductivity.

[0076] For example, the first thermally conductive flange 21 and the second thermally conductive flange 22 have a thickness between 1 and 15 mm. Therefore, the thermally conductive flanges are lighter and have improved thermal conductivity.

[0077] The first thermally conductive flange 21 and the second thermally conductive flange 22 may include removable assembly components. For example, a removable assembly component is a retaining screw 26.

[0078] The temperature-regulating and heat-conducting mold 23 is preferably made of steel. The temperature-regulating and heat-conducting mold 23 is preferably regulated by a heat transfer fluid (e.g., water).

[0079] The upper cavity 24 of the temperature-regulating and heat-conducting mold 23 is fastened to the upper pressure plate 31 of the press 3, and the lower cavity 25 of the temperature-regulating and heat-conducting mold 23 is fastened to the lower pressure plate 32. The first heat-conducting flange 21 and the second heat-conducting flange 22 are removable, that is, independent of the temperature-regulating and heat-conducting mold 23 and the press 3.

[0080] In this example, system 1 includes a vacuum device 11.

[0081] In this example, system 1 further includes a transfer frame 12 that allows the transfer of the first thermally conductive flange 21 and the second thermally conductive flange 22, and a guide rail 14 that is fixed on the lateral guide support 13 to allow the first thermally conductive flange 21, the second thermally conductive flange 22, and the transfer frame 12 to be guided.

[0082] A method for manufacturing a thermoplastic compound using system 1 for manufacturing thermoplastic compounds includes step A), wherein a thermoplastic prepreg fabric comprising fibers and a thermoplastic matrix is ​​provided.

[0083] Figure 3 and Figure 4Step B is shown, in which the thermoplastic prepreg fabric 4 is inserted into the first thermally conductive flange 21 and the second thermally conductive flange 22. For this purpose, the thermoplastic prepreg fabric 4 can be deposited on the second thermally conductive flange 22. Then, the first flange 21 can be deposited on the second thermally conductive flange 22 to define a cavity configured to receive the thermoplastic prepreg fabric 4. The first thermally conductive flange 21 and the second thermally conductive flange 22 can then be assembled using a locking screw 26. Figure 5 ).

[0084] For example, in step A), the thermoplastic prepreg fabric 4 comprises fibers selected from: short or continuous fibers, natural fibers, organic fibers, or mineral fibers. For example, the fibers are selected from: basalt fibers, carbon fibers, and glass fibers. For example, in step A), the thermoplastic matrix is ​​composed of polyolefins, polycarbonates, polyamides, polystyrene, polyesters, and / or polyaryletherketones. For example, a thermoplastic matrix made of polyphenylene sulfide, a thermoplastic matrix made of polyethylene, or a thermoplastic matrix made of polyethylene terephthalate.

[0085] Figure 6 Step C) is shown, in which the first thermally conductive flange 21 and the second thermally conductive flange 22 are transferred into the press 3. For this purpose, the first thermally conductive flange 21 and the second thermally conductive flange 22 are arranged on the track 14.

[0086] Figure 3 and Figure 7 Step D) is shown, wherein the first thermally conductive flange 21 and the second thermally conductive flange 22 are preheated by the mold 23 in the press 3. Preheating of the mold 23 can be carried out by convection or conduction at a temperature between 50 and 150°C, for example, at 100°C. Preheating can take 1 to 10 minutes, for example, 5 minutes.

[0087] Figure 3 and Figure 7 Step E) is also shown, in which the first thermally conductive flange 21 and the second thermally conductive flange 22 are pressed. The pressing can be performed in a 10×10... 6 and 60×10 6 The test is conducted at a pressure between Pa, and for example at a pressure equal to 15 × 10 Pa. 6 The test was conducted under a pressure of Pa.

[0088] Figure 7 Step M), which can be performed after step E), is also shown, including evacuating the first thermally conductive flange 21 and the second thermally conductive flange 22 using a vacuum device 11. For example, a heat-resistant seal is inserted between the first thermally conductive flange 21 and the second thermally conductive flange 22. The seal may have a compressibility factor ranging from 0.1 to 3 mm, and for example, a compressibility factor of 1.5 mm.

[0089] Figure 8 The opening of the press 3 is shown. Then, the first thermally conductive flange 21 and the second thermally conductive flange 22 can be mounted on the transfer frame 12. Figure 1 In step F), the first thermally conductive flange 21 and the second thermally conductive flange 22 are transferred into the infrared (IR) oven.

[0090] Figure 3 and Figure 9 Step G) is shown, in which the first thermally conductive flange 21 and the second thermally conductive flange 22 are heated in an infrared (IR) oven. For example, the first thermally conductive flange 21 and the second thermally conductive flange are heated at the melting temperature of the thermoplastic matrix of the thermoplastic pre-impregnated fabric. The heating of the first thermally conductive flange 21 and the second thermally conductive flange 22 can be performed for 5 to 15 minutes or, for example, 8 minutes.

[0091] Figure 10 The opening of the press 3 is shown. Then, the first thermally conductive flange 21 and the second thermally conductive flange 22 can be mounted on the transfer frame 12. Figure 1 In step H), the first thermally conductive flange 21 and the second thermally conductive flange 22 are transferred into the press 3.

[0092] Figure 3 and Figure 11 Step I) is shown, in which the first thermally conductive flange 21 and the second thermally conductive flange 22 are cooled. For example, the first thermally conductive flange 21 and the second thermally conductive flange 22 are cooled at a temperature at least 10°C lower than the glass transition temperature of the thermoplastic matrix. Cooling can be carried out for 1 to 10 minutes or, for example, 6 minutes.

[0093] Figure 3 and Figure 11 Step J) is also shown, in which the first thermally conductive flange 21 and the second thermally conductive flange 22 are pressed. The pressing can be performed in a 10×10... 6 and 60×10 6 The test is conducted at a pressure between Pa, and for example at a pressure equal to 15 × 10 Pa. 6 The test was conducted under a pressure of Pa.

[0094] Figure 11 Step M), which can be performed after step J), is also shown, including evacuating the first thermally conductive flange 21 and the second thermally conductive flange 22 using a vacuum device 11. For example, a heat-resistant seal is inserted between the first thermally conductive flange 21 and the second thermally conductive flange 22. The seal may have a compressibility factor ranging from 0.1 to 3 mm, and for example, a compressibility factor of 1.5 mm.

[0095] Figure 12 The image shows the compressor 3 opening when cooling is complete.

[0096] Figure 13Step K) is shown, in which the first thermally conductive flange 21 and the second thermally conductive flange 22 are extracted from the press 3. After the first thermally conductive flange 21 is removed, the thermoplastic composite 41 can be demolded. For example, the thickness of the part made of the thermoplastic composite includes between 1 and 50 mm, preferably between 1 and 10 mm, and for example, 2 mm.

[0097] When implementing the method according to the invention, two separate presses may be used during steps C) and H).

[0098] The molding apparatus according to the invention facilitates the molding of thermoplastic prepreg fabrics. Furthermore, the energy efficiency of the method for manufacturing thermoplastic composites is improved. Additionally, the removable thermally conductive flanges allow for better consolidation of the thermoplastic prepreg fabrics, while also benefiting the method for manufacturing thermoplastic composites. The method for manufacturing thermoplastic composites can be implemented on an industrial scale, particularly continuously. Furthermore, the first and second thermally conductive flanges, as well as the temperature-regulating and heat-conducting mold, have compatible thermal expansion to ensure control of the thermoplastic composite dimensions. Finally, the first and second thermally conductive flanges ensure optimal heat transfer and guarantee temperature uniformity within them, while maintaining the best quality of the thermoplastic composite.

Claims

1. A method for manufacturing a thermoplastic compound (41) using a system (1) for manufacturing thermoplastic compounds, said system comprising: A molding apparatus (2) includes a first thermally conductive flange (21) and a second thermally conductive flange (22), the first and second thermally conductive flanges (21 and 22) defining a cavity configured to receive a thermoplastic prepreg fabric (4), and a mold (23) conditioned and heated by a heat transfer fluid, the mold including an upper mold (24) and a lower mold (25), the upper mold (24) and the lower mold (25) being configured to receive the first thermally conductive flange (21) and the second thermally conductive flange (22), and The press (3) includes an upper pressure plate (31) and a lower pressure plate (32). The upper die (24) of the temperature-regulating and heat-conducting mold (23) is fastened to the upper pressure plate, and the lower die (25) of the temperature-regulating and heat-conducting mold (23) is fastened to the lower pressure plate. A method for manufacturing a thermoplastic compound includes the following steps: A. Provides thermoplastic prepreg fabrics comprising fibers and a thermoplastic matrix (4), B. Insert the thermoplastic prepreg fabric (4) into the first thermally conductive flange (21) and the second thermally conductive flange (22). C. Transfer the heat-conducting flanges (21, 22) into a press (3), the press comprising a mold (23) that is temperature-controlled and heat-conducted by a heat transfer fluid. D. The heat-conducting flanges (21, 22) are preheated using the mold in the press. E. Press down the thermally conductive flanges (21, 22). F. Transfer the heat-conducting flanges (21, 22) into an infrared (IR) oven. G. Heating the thermally conductive flanges (21, 22) under infrared light to melt the thermoplastic matrix. H. The heat-conducting flanges (21, 22) are transferred to a press (3) comprising a mold (23) that is conditioned and heated by a heat transfer fluid. I. Cooling the heat-conducting flanges (21, 22) in the press (3), J. Press the heat-conducting flanges (21, 22) in the press (3), K. Extract the thermally conductive flanges (21, 22) from the press (3), and L. Demold the thermoplastic composite (41).

2. The method for manufacturing a thermoplastic compound according to claim 1, wherein in step D), the preheating of the mold (23) is carried out by convection or by conduction.

3. The method of manufacturing a thermoplastic compound according to claim 1 or 2, wherein in step D), the preheating of the mold (23) is carried out at a temperature between 50 and 150°C.

4. The method for manufacturing a thermoplastic composite according to any one of claims 1 to 3, wherein in steps E) and / or J), pressing is performed in a 10 × 10 6 Up to 60×10 6 The test is conducted under pressures between Pa.

5. The method of manufacturing a thermoplastic composite according to any one of claims 1 to 4, comprising step M) performed after step E) or J), comprising evacuating the first thermally conductive flange (21) and the second thermally conductive flange (22).

6. The method of manufacturing a thermoplastic compound according to claim 5, wherein a seal is inserted between the first thermally conductive flange (21) and the second thermally conductive flange (22).

7. The method of manufacturing a thermoplastic composite according to any one of claims 1 to 6, wherein in step G), the first thermally conductive flange (21) and the second thermally conductive flange (22) are heated at the melting temperature of the thermoplastic matrix of the thermoplastic prepreg fabric (4).

8. The method of manufacturing a thermoplastic composite according to any one of claims 1 to 7, wherein in step I), the first thermally conductive flange (21) and the second thermally conductive flange (22) are cooled at a temperature at least 10°C lower than the glass transition temperature of the thermoplastic matrix.

9. The method of manufacturing a thermoplastic composite according to any one of claims 1 to 8, wherein the thermoplastic prepreg fabric (4) comprises electronic components based on inorganic or organic compounds.

10. The method of manufacturing a thermoplastic composite according to any one of claims 1 to 9, wherein the first thermally conductive flange (21) and the second thermally conductive flange (22) have a thermal conductivity greater than 30 W·m. -1 ·K -1 The thermal conductivity of the mold (23), which is conditioned and conducted by the heat transfer fluid, is greater than 30 W·m. -1 ·K -1 Thermal conductivity.

11. The method of manufacturing a thermoplastic composite according to any one of claims 1 to 10, wherein the first thermally conductive flange (21) and the second thermally conductive flange (22) are made of steel, aluminum or thermosetting composite material coated with black oxide.

12. The method of manufacturing a thermoplastic compound according to any one of claims 1 to 11, wherein the first thermally conductive flange (21) and the second thermally conductive flange (22) comprise removable assembly devices.

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